Skip to main content
SpringerLink
Log in

Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Drilling of micro-hole with fine edges and smooth internal surfaces finds numerous applications in manufacturing industries; holes drilled in injection nozzles, drug delivery orifices and spinneret holes are some of examples. This work carries out an experimental investigation and parametric optimization on micro-hole drilling using micro-electrical discharge machining (µ-EDM) process. The machining experiments are conducted employing Taguchi L16 orthogonal array for evaluating machining time (t) average overcut (AOV), taper angle (TA), entry overcut (EnOV), exit overcut (ExOV) and material removal rate (MRR) as process performances, while voltage (V), capacitance (pF) and feed rate (µm/s) are considered as process parameters. The influence of process parameters on the responses is studied at different cutting conditions. The drilled micro-holes profile is studied in terms of burrs, craters, spots on the edges and internal surfaces using micrographs obtained with optical and scanning electron microscopes. The ANOVA result reveals that capacitance is the most significant parameter for t, AOV, TA, MRR, EnOV and ExOV. For simultaneous optimization of three performance measures (i.e., t, AOV and TA), an overall evaluation criterion has been evaluated and optimum cutting conditions such as voltage: 80 V, capacitance: 100 pF and feed rate: 15 µm/s are obtained. The expected outcome obtained at the optimum condition is improved by 10.57% (36.934 to 40.839) over the grand average of performance. The confirmation experimental result at optimum cutting condition (i.e., 39.378) is comparable with the expected result (i.e., 40.839).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Agrawal D, Kamble D (2019) Effect and optimization of photochemical machining process parameters for manufacturing array of micro-hole. J Braz Soc Mech Sci Eng. https://doi.org/10.1007/s40430-019-1678-y

    Article  Google Scholar 

  2. Rajamanickam S, Prasanna J, Chandrasekhara Sastry C (2020) Analysis of high aspect ratio small holes in rapid electrical discharge machining of superalloys using Taguchi and TOPSIS. J Braz Soc Mech Sci Eng. https://doi.org/10.1007/s40430-020-2180-2

    Article  Google Scholar 

  3. Kumar V, Singh H (2019) Investigation of hole quality in rotary ultrasonic drilling of borosilicate glass using RSM. J Braz Soc Mech Sci Eng. https://doi.org/10.1007/s40430-018-1524-7

    Article  Google Scholar 

  4. Singh AK, Patowari PK, Deshpande NV (2013) Micro-hole drilling on thin sheet metals by micro-electro discharge machining. J Manuf Technol Res 5:137

    Google Scholar 

  5. Yi SM, Park MS, Lee YS, Chu CN (2008) Fabrication of a stainless steel shadow mask using batch mode micro-EDM. Microsyst Technol 14:411–417. https://doi.org/10.1007/s00542-007-0468-0

    Article  Google Scholar 

  6. Yi SM, Jin SH, Lee JD, Chu CN (2005) Fabrication of a high-aspect-ratio stainless steel shadow mask and its application to pentacene thin-film transistors. J Micromech Microeng 15:263–269. https://doi.org/10.1088/0960-1317/15/2/003

    Article  Google Scholar 

  7. Qin G, Qu YD, Jin ML et al (2015) Preparation of ultra-high aspect ratio micro holes by casting. J Mater Process Technol 217:144–147. https://doi.org/10.1016/j.jmatprotec.2014.11.012

    Article  Google Scholar 

  8. Baghel R, Singh Mali H (2018) A study on effects of discharge energy on geometric characteristics of high aspect ratio micro-holes on TiN–Al2O3 ceramics. In: Materials today: proceedings. Elsevier Ltd, pp 17828–17837

  9. Singh AK, Kar S, Patowari PK (2020) Accuracy improvement and precision measurement on micro-EDM. In: Accuracy enhancement technologies for micromachining processes. Springer, pp 47–77

  10. Puranik MS, Joshi SS (2008) Analysis of accuracy of high-aspect-ratio holes generated using micro-electric discharge machining drilling. Proc Inst Mech Eng Part B J Eng Manuf 222:1453–1464. https://doi.org/10.1243/09544054JEM1186

    Article  Google Scholar 

  11. Kim BH, Park BJ, Chu CN (2006) Fabrication of multiple electrodes by reverse EDM and their application in micro ECM. J Micromech Microeng 16:843–850. https://doi.org/10.1088/0960-1317/16/4/022

    Article  Google Scholar 

  12. Singh AK, Patowari PK, Deshpande NV (2019) Analysis of micro-rods machined using reverse micro-EDM. J Braz Soc Mech Sci Eng 41:15. https://doi.org/10.1007/s40430-018-1519-4

    Article  Google Scholar 

  13. Singh AK, Patowari PK, Deshpande NV (2017) Effect of tool wear on microrods fabrication using reverse μEDM. Mater Manuf Process 32:286–293. https://doi.org/10.1080/10426914.2016.1198015

    Article  Google Scholar 

  14. Singh AK, Patowari PK, Deshpande NV (2016) Experimental analysis of reverse micro-EDM for machining microtool. Mater Manuf Process 31:530–540. https://doi.org/10.1080/10426914.2015.1070426

    Article  Google Scholar 

  15. Natarajan N, Suresh P (2015) Experimental investigations on the microhole machining of 304 stainless steel by micro-EDM process using RC-type pulse generator. Int J Adv Manuf Technol 77:1741–1750. https://doi.org/10.1007/s00170-014-6494-z

    Article  Google Scholar 

  16. Pragadish N, Pradeep Kumar M (2016) Optimization of dry EDM process parameters using grey relational analysis. Arab J Sci Eng 41:4383–4390. https://doi.org/10.1007/s13369-016-2130-6

    Article  Google Scholar 

  17. Ay M, Çaydaş U, Hasçalık A (2013) Optimization of micro-EDM drilling of Inconel 718 superalloy. Int J Adv Manuf Technol 66:1015–1023. https://doi.org/10.1007/s00170-012-4385-8

    Article  Google Scholar 

  18. Grigor’ev SN, Kuzin VV, Fedorov SY et al (2014) Technological aspects of the electrical-discharge machining of small-diameter holes in a high-density ceramic. Part 1. Refract Ind Ceram 55:330–334. https://doi.org/10.1007/s11148-014-9720-1

    Article  Google Scholar 

  19. Tong H, Li Y, Zhang L, Li B (2013) Mechanism design and process control of micro EDM for drilling spray holes of diesel injector nozzles. Precis Eng 37:213–221. https://doi.org/10.1016/j.precisioneng.2012.09.004

    Article  Google Scholar 

  20. Ferraris E, Castiglioni V, Ceyssens F et al (2013) EDM drilling of ultra-high aspect ratio micro holes with insulated tools. CIRP Ann Manuf Technol 62:191–194. https://doi.org/10.1016/j.cirp.2013.03.115

    Article  Google Scholar 

  21. Jahan MP, Wong YS, Rahman M (2012) Evaluation of the effectiveness of low frequency workpiece vibration in deep-hole micro-EDM drilling of tungsten carbide. J Manuf Process 14:343–359. https://doi.org/10.1016/j.jmapro.2012.07.001

    Article  Google Scholar 

  22. Ekmekci B, Sayar A (2013) Debris and consequences in micro electric discharge machining of micro-holes. Int J Mach Tools Manuf 65:58–67. https://doi.org/10.1016/j.ijmachtools.2012.10.003

    Article  Google Scholar 

  23. Jiang Y, Zhao W, Xi X (2012) A study on pulse control for small-hole electrical discharge machining. J Mater Process Technol 212:1463–1471. https://doi.org/10.1016/j.jmatprotec.2012.01.022

    Article  Google Scholar 

  24. Pandey RK, Panda SS (2015) Multi-performance optimization of bone drilling using Taguchi method based on membership function. Measurement 59:9–13. https://doi.org/10.1016/J.MEASUREMENT.2014.09.038

    Article  Google Scholar 

  25. Li B, Nye TJ, Metzger DR (2006) Multi-objective optimization of forming parameters for tube hydroforming process based on the Taguchi method. Int J Adv Manuf Technol 28:23–30. https://doi.org/10.1007/s00170-004-2338-6

    Article  Google Scholar 

  26. Gaitonde VN, Karnik SR, Achyutha BT, Siddeswarappa B (2008) Taguchi optimization in drilling of AISI 316L stainless steel to minimize burr size using multi-performance objective based on membership function. J Mater Process Technol 202:374–379. https://doi.org/10.1016/J.JMATPROTEC.2007.08.013

    Article  Google Scholar 

  27. Tamang SK, Natarajan N, Chandrasekaran M (2017) Optimization of EDM process in machining micro holes for improvement of hole quality. J Braz Soc Mech Sci Eng 39:1277–1287. https://doi.org/10.1007/s40430-016-0630-7

    Article  Google Scholar 

  28. Gaitonde VN, Karnik SR, Achyutha BT, Siddeswarappa B (2007) Methodology of Taguchi optimization for multi-objective drilling problem to minimize burr size. Int J Adv Manuf Technol 34:1–8. https://doi.org/10.1007/s00170-006-0571-x

    Article  Google Scholar 

  29. Bhatt RJ, Raval HK (2018) Investigation on flow forming process using Taguchi-based grey relational analysis (GRA) through experiments and finite element analysis (FEA). J Braz Soc Mech Sci Eng 40:1–24. https://doi.org/10.1007/s40430-018-1456-2

    Article  Google Scholar 

  30. Malik A, Manna A (2018) Multi-response optimization of laser-assisted jet electrochemical machining parameters based on gray relational analysis. J Braz Soc Mech Sci Eng 40:1–21. https://doi.org/10.1007/s40430-018-1069-9

    Article  Google Scholar 

  31. Hu D, Liu Y, Zhou X (2018) The use of function-driven shape definition method and GRA–EMM-based Taguchi method to multi-criterion blade preform optimization. J Braz Soc Mech Sci Eng 40:1–14. https://doi.org/10.1007/s40430-018-1369-0

    Article  Google Scholar 

  32. Samavi J, Goharimanesh M, Akbari A, Dezyani E (2018) Optimisation of drilling parameters on St37 based on Taguchi method. J Braz Soc Mech Sci Eng 40:1–9. https://doi.org/10.1007/s40430-018-1245-y

    Article  Google Scholar 

  33. Meran C (2006) The joint properties of brass plates by friction stir welding. Mater Des 27:719–726. https://doi.org/10.1016/J.MATDES.2005.05.006

    Article  Google Scholar 

  34. Fard MJB, Bordatchev EV (2013) Experimental study of the effect of tool orientation in five-axis micro-milling of brass using ball-end mills. Int J Adv Manuf Technol 67:1079–1089. https://doi.org/10.1007/s00170-012-4549-6

    Article  Google Scholar 

  35. Roy RK (2001) Design of experiments using the Taguchi approach: 16 steps to product and process improvement. Wiley, New York

    Google Scholar 

  36. Patowari PK, Saha P, Mishra PK (2011) Taguchi analysis of surface modification technique using W-Cu powder metallurgy sintered tools in EDM and characterization of the deposited layer. Int J Adv Manuf Technol 54:593–604. https://doi.org/10.1007/s00170-010-2966-y

    Article  Google Scholar 

Download references

Acknowledgements

The authors are thankful to anonymous reviewers for their comments that help to improve the quality of this manuscript. The authors acknowledge SAIF, North Eastern Hill University (NEHU), Shillong, Meghalaya, India, for obtaining characterization of the work specimens.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Nagaland, Dimapur, Nagaland, 796012, India

    Amit Kumar Singh

  2. Department of Mechanical Engineering, National Institute of Technology Silchar, Silchar, Assam, India

    Promod Kumar Patowari

  3. Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Itanagar, Arunachal Pradesh, India

    M. Chandrasekaran

Authors
  1. Amit Kumar Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Promod Kumar Patowari
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. M. Chandrasekaran
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Amit Kumar Singh.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Technical Editor: Adriano Fagali de Souza.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, A.K., Patowari, P.K. & Chandrasekaran, M. Experimental study on drilling micro-hole through micro-EDM and optimization of multiple performance characteristics. J Braz. Soc. Mech. Sci. Eng. 42, 506 (2020). https://doi.org/10.1007/s40430-020-02595-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-020-02595-w

Keywords

Search

Navigation