Micro electric discharge milling process performance: An experimental investigation

Karthikeyan, G.; Ramkumar, J.; Dhamodaran, S.; Aravindan, S.

doi:10.1016/j.ijmachtools.2010.04.007

Cited by 69 publications

(22 citation statements)

References 24 publications

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“…Initially, it helps the dielectric fluid to pull out the debris from the inter electrode gap with the influence of a centrifugal force. Secondly, ERS produces an agitation effects, this helps the dielectric fluid to go into the discharge zone [16]. Thus it results in more effective sparks in the discharge zoon and increase in the MRR.…”

Section: Analysis Of Mrrmentioning

confidence: 99%

“…In addition, the effect of various process variables on MRR, circularity, overcut and heat affected zone were investigated and reported that 'Cu' electrode gave maximum MRR. Karthikeyan et al [16] had conducted an experimental investigation of micro electric discharge milling of EN24 steel. Effect of parameters like speed, feed, discharge energy and aspect ratio on MRR and TWR were analyzed.…”

Section: Introductionmentioning

confidence: 99%

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Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti–6Al–4V

Kuriachen

Mathew

2014

Materials and Manufacturing Processes

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Micro electric discharge milling is acquiring more importance in micro manufacturing because of its unique ability to produce three dimensional micro cavities with high aspect ratio in electrically conductive advanced materials regardless of its mechanical properties. The present study investigates the effects of major micro electric -discharge milling process variables (Voltage (V), Capacitance(C), electrode rotational speed (ERS) and feed rate (FR)) on Ti-6Al-4V. The output performance measures were identified as material removal rate (MRR) and tool wear rate (TWR) to assess the machinability of Ti-6AL-4V. Experiments were designed and carried out based on response surface methodology-Box Behnken statistical design. The most influencing parameters for responses (MRR, TWR) were found to be capacitance and feed rate. At a capacitance of 0.4 µF and feed rate of 18 mm/min, maximum MRR of 0.9756 mg/hr and TWR of 0.6342 mg/hr were observed. Similarly at 0.01 µF and 6mm/min, minimum MRR of 0.2308 mg/hr and TWR of 0.1259 mg/hr were obtained. Downloaded by [UNAM Ciudad Universitaria] at 20:25 25 December 2014 2

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Section: Analysis Of Mrrmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti–6Al–4V

Kuriachen

Mathew

2014

Materials and Manufacturing Processes

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“…It is a statistical method that uses quantitative data from experiments to determine and simultaneously solve multi-variant equations. Karthikeyan et al [11] conducted general factorial experiments for microEDM in order to present an exhaustive study of parameters on the material removal rate (MRR) and the tool wear rate (TWR). Kung et al [12] introduced powder-mixed EDM when machining cobalt-bonded tungsten carbide.…”

Section: Optimization Of Intervening Variables In Microedm Of Ss 316lmentioning

confidence: 99%

Optimization of Intervening Variables in MicroEDM of SS 316L using a Genetic Algorithm and Response-Surface Methodology

Suresh¹,

Venkatesan²,

Sekar³

et al. 2014

SV-JME

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This research paper attempts to investigate the optimum values of the major intervening parameters in micro-Electric Discharge Machining (microEDM) of Stainless Steel (SS) 316L. Experiments are conducted using a 400 micrometre brass electrode. The discharge current, pulseon time and pulse-off time with three levels are selected as significant intervening parameters. The Taguchi method is initially applied to determine the optimum process parameters and the number of experiments required to model the responses. The response-surface methodology (RSM) is applied to correlate between intervening parameters, and the selected objectives to maximize the material removal rate (MRR) and to minimize the tool wear rate (TWR) in the machining of SS 316 L. The mathematical model obtained from RSM is used as a fitness function to multi-objective optimization using a genetic algorithm (GA). The results reveal that the resulting optimal intervening parameters improve the chosen objectives significantly. The confirmation results prove that the better developed mathematical model yields deviate within 5% of the experiment.

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“…Different groups examine the single process parameters (e.g. discharge voltage, peak current, pulse properties, polarity, electrode gap), their interaction (Mahendran et al 2010) and the improvement of the process performance (Karthikeyan et al 2010). Despite the high number of publications referring to the improved capabilities of this technique, it is still not widely employed.…”

Section: Microelectrical Discharge Machiningmentioning

confidence: 99%

Novel 3D manufacturing method combining microelectrial discharge machining and electrochemical polishing

2012

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This paper reports on the potential of microelectrical discharge machining (lEDM) as an innovative method for the fabrication of 3D microdevices. To demonstrate the wide capabilities of lEDM two different microsystems-a microfluidic device for the dispersion of nanoparticles and a star probe for microcoordinate metrology-are presented. To gain optimized process conditions as well as a high surface quality an adequate adaption of the single erosion parameters such as energy, pulse frequency and spark gap has to be carried out and is discussed below. Thus, a surface roughness of R a = 80 nm is achieved at the channel bottom. The fabricated stylus elements for the star probe have sphere diameters of 40-200 lm. For further surface quality enhancement a subsequent electrochemical polishing step is investigated. In case of the dispersion micromodule a combined process chain of lEDM-milling and electropolishing has reached a surface improvement above 70%.

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Micro electric discharge milling process performance: An experimental investigation

Cited by 69 publications

References 24 publications

Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti–6Al–4V

Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti–6Al–4V

Optimization of Intervening Variables in MicroEDM of SS 316L using a Genetic Algorithm and Response-Surface Methodology

Novel 3D manufacturing method combining microelectrial discharge machining and electrochemical polishing

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