Skip to main content

High Aspect Ratio Micro-EDM Drilling with Nano Surface Finish


This paper presents the issues related to high aspect ratio in micro drilling on metallic materials using micro electro discharge machining (Micro-EDM). Experimental investigation is carried out by drilling high aspect ratio micro holes on copper workpiece with 1 mm diameter tungsten carbide tool electrode using micro-EDM DT 110 with two varying parameters voltage and capacitance. For the measurement and observation of aspect ratio, roundness, and surface roughness were performed by scanning electron microscope, optical microscope, and WYKO NT1100 optical profiler respectively. The purpose of this paper is to achieve high aspect ratio, accurate roundness, and low surface roughness with the minimum wear of tool electrode within machining time. The data were analyzed by Design Expert software. Emperical models for aspect ratio, roundness, and surface roughness are developed. The analysis revealed that the most influential parameter is capacitance. Multiple optimization of responses showed that the optimum parameter values are 90 V gap voltage and 0.26 µF capacitance which provide 2.4 aspect ratio, 44 µm roundness, and 6.0 µm Ra surface roughness. The desirability achieved by optimization is 73.9%. The models are validated by experiments.


  • High aspect ratio
  • Micro-EDM
  • Micro-hole
  • Nano surface finish
  • Roundness

This is a preview of subscription content, access via your institution.

Buying options

USD   29.95
Price excludes VAT (USA)
  • DOI: 10.1007/978-981-10-0534-3_15
  • Chapter length: 8 pages
  • Instant PDF download
  • Readable on all devices
  • Own it forever
  • Exclusive offer for individuals only
  • Tax calculation will be finalised during checkout
USD   129.00
Price excludes VAT (USA)
  • ISBN: 978-981-10-0534-3
  • Instant PDF download
  • Readable on all devices
  • Own it forever
  • Exclusive offer for individuals only
  • Tax calculation will be finalised during checkout
Softcover Book
USD   169.00
Price excludes VAT (USA)
Hardcover Book
USD   219.99
Price excludes VAT (USA)
Fig. 1
Fig. 2
Fig. 3
Fig. 4


  • Azlan AR, Azuddin M, Wagiman A (2009) Effect of machining parameters on hole quality of micro drilling for brass. J Mod Appl Sci 3(5):27–30

    Google Scholar 

  • Billa S, Sundaram MM, Rajukar KP (2010) A study on the high aspect ratio micro hole drilling using ultrasonic assisted micro electro discharge machining. In: Proceedings of the ASPE 2007 Spring Topical Meeting, vol 40, pp 32–36

    Google Scholar 

  • Chow HM, Yang LD, Lin CT, Chen YF (2008) The use of SiC powder in water as dielectric for micro slit EDM machining. J Mater Process Technol 195(1–3):160–170

    CrossRef  Google Scholar 

  • Lim HS, Wong YS, Rahman M, Edwin MKL (2003) A study on the machining of high aspect ratio microstructures using micro EDM. J Mater Process Technol 140(1–3):318–325

    CrossRef  Google Scholar 

  • Murali M, Yeo SH (2004) Rapid biocompatible micro device fabrication by micro electro discharge machining. Biomed Microdevices 6(1):41–45

    CrossRef  Google Scholar 

Download references


This research was conducted under the Science Fund grant 03-01-08-SF0135 and Fundamental Research Grant Scheme FRGS12-074-0223 from Ministry of Science and Technology and Ministry of Education of Malaysia. The authors are grateful to the micromanufacturing laboratory where the experimental studies were conducted.

Author information

Authors and Affiliations


Corresponding author

Correspondence to Mohammad Yeakub Ali .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and Permissions

Copyright information

© 2016 Springer Science+Business Media Singapore

About this paper

Cite this paper

Ali, M.Y., Abd Rahman, M., Banu, A., Adnan, S., Nadia, F. (2016). High Aspect Ratio Micro-EDM Drilling with Nano Surface Finish. In: Yacob, N., Mohamed, M., Megat Hanafiah, M. (eds) Regional Conference on Science, Technology and Social Sciences (RCSTSS 2014). Springer, Singapore.

Download citation