Reverse micro EDMed 3D hemispherical protruded micro feature: microstructural and mechanical characterization

Electrical discharge machined surfaces inherently possess recast layer on the surface with heat affected zone (HAZ) beneath it and these have a detrimental effect on the mechanical properties viz. hardness, elastic modulus, etc. It is very difficult to experimentally characterise each machined surface. Therefore, an attempt is made in this study to numerically calculate the mechanical properties of the parent material, HAZ and the recast layer on a hemispherical protruded micro feature fabricated by reverse micro EDM (RMEDM). In the 1st stage, nano indentation was performed to experimentally determine the load-displacement plots, elastic modulus and hardness of the parent material, HAZ and the recast layer. In the 2nd stage, FEA simulation was carried out to mimic the nano indentation process and determine the load-displacement plots for all the three cases viz. parent material, recast layer and HAZ. Results demonstrated that the load'displacement plots obtained from numerical model in each case was in good agreement with that of the experimental curves. Based on simulated load-displacement plots, hardness was also calculated for parent material, HAZ and the recast layer. A maximum of 11% error was observed between simulated values of hardness and experimentally determined values.

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Controlling recast layer and material removal in reverse µEDM for sustainable fabrication of microelectrode arrays

Pratap,

Datta,

Sharma

2024

Proceedings of the Institution of Mechanical Engineers, Part E:

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Microelectrode arrays (MEAs) are essential for researching neurons and heart tissue because they record and stimulate neuronal activity. For manufacturing MEAs on conductive materials, reverse microelectrical discharge machining, or reverse µEDM, presents a viable method. However, achieving precise MEAs requires control over recast layers generated during micromachining. This study focuses on recast layer thickness (RLT) and material removal rate (MRR) as key performance indicators for sustainable reverse µEDM fabrication of MEAs. RLT affects surface stability, while MRR influences energy consumption and cost. Optimising these responses depends on three input factors: feed rate, capacitance, and voltage. ANOVA analysis reveals that capacitance is crucial in both MRR and recast layer thickness (RLT) in reverse µEDM, contributing to 88.71% and 94.04% simultaneously. A hybrid artificial neural network-genetic algorithm for global optimisation was employed. The optimised parameters 46.5nF capacitance, 110 V voltage, and 5 µm/sec feed yielded a minimum RLT of 1.58 µm and a maximum MRR of 0.3 mm³/min. These advancements signify significant improvements in the precision and efficiency of MEAs fabrication through reverse µEDM, contributing to its sustainable implementation.

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Reverse micro EDMed 3D hemispherical protruded micro feature: microstructural and mechanical characterization

Cited by 3 publications

References 16 publications

Fabrication, characterization and comparative analysis of mechanical properties of micro features generated by reverse micro EDM

Fabrication, characterization and comparative analysis of mechanical properties of micro features generated by reverse micro EDM

Modeling the Nano Indentation Behavior of Recast Layer and Heat Affected Zone on Reverse Micro EDMed Hemispherical Feature

Controlling recast layer and material removal in reverse µEDM for sustainable fabrication of microelectrode arrays

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