Micro dry wire electrical discharge machining (μDWEDM) is a process where gas is used as the dielectric fluid instead of a liquid. In this process , certain modifications of wire electrical discharge machining (WEDM) are needed during the machining operation to achieve stable machining. Smooth and stable machining operation in μDWEDM process remains as a critical issue. Thus, this paper presents the investigation of process parameters for a stable μDWEDM process. The investigation was performed on a stainless steel (SS304) with a tungsten wire as the electrode using integrated multi-process machine tool, DT 110 (Mikrotools Inc., Singapore). View all related documents based on references

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In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap.

Electro discharge machining (EDM) process is a non-conventional and non-contact machining operation which is used in industry for high precision products. EDM is known for machining hard and brittle conductivematerials since it can melt any electrically conductive material regardless of its hardness. The workpiece machined by EDM depends on thermal conductivity, electrical resistivity, and melting points of the materials. The tool and the workpiece are adequately both immersed in a dielectric medium, such as, kerosene, deionised water or any other suitable fluid. This paper is reviewed comprehensively on types of EDM operation. A brief discussion is also done on the machining responses and mathematical modelling.

Micro dry wire electrical discharge machining (μDWEDM) is an environmental-friendly machining process where gas is used as the dielectric fluid instead of liquid. In this process, certain modifications of wire electrical discharge machining (WEDM) are required during the machining operation for stable machining. In μDWEDM, the process is considered stable if the machining is continuous without any interruption due to wire breakage or wire lag. However, in the present state of the arts, stable and smooth machining process using μDWEDM remains a critical issue. Hence, the objectives of this research are to establish a stable μDWEDM process using two different experimental approaches: one-factor-at-a-time (OFAT) and design of experiment (DOE) method. The investigation was performed on a stainless steel (SS304) with a tungsten wire as the electrode using integrated multiprocess machine tool, DT 110 (Mikrotools Inc., Singapore). Types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, wire speed, gap voltage, and capacitance were the controlled parameters. The machining length of the microchannels was measured using scanning electron microscope (SEM) (JEOL JSM-5600, Japan). Analysis based on these two experimental approaches shows that stable μDWEDM process is achievable when the types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, and wire speed remain as the fixed parameters while the capacitance and gap voltage remain as the controlled parameters.