Performance analysis and process optimization of micro edm of die steel with different electrodes

Abstract

Rapid advancement in manufacturing industries and increasing newlinedemand for micro-parts has given rise to advancement in micro newlinemanufacturing techniques. In recent years, numerous developments in micro- newlineEDM focus on the fabrication of micro-holes, micro-tools and micro newlinecomponents. Although micro-holes are formed by different manufacturing newlinemethods, micro-EDM proves to be one of the most promising manufacturing newlinetechnologies. Even though, micro-EDM is found to be capable of newlinemanufacturing micro-holes regardless of hardness, the study on quality and newlineintegrity of discharge machined surface is shown important as it has a newlinesignificant impact on the product performance. Since an electrode with micro features is employed to cut its newlinemirror image in the workpiece, it is necessary to investigate the machining newlineefficiency of the electrodes used. Furthermore, to improve the machining newlineefficiency, it is momentous to consider the effect of various influencing input newlineand output parameters. newlineIn this study, a series of experiments were conducted with various newlineelectrodes such as tungsten, copper, copper tungsten and silver tungsten of newline300and#956;m diameter as a tool and EN24 die steel as workpiece to machine blind newlineholes of 500and#956;m depth on the workpiece using RC type generator. The combination of gap voltage, capacitance, feed rate and threshold setting were newlineconsidered for maximum Material Removal Rate (MRR), lower Tool Wear newlineRatio (TWR), Surface Roughness (SR), constrained circularity error and newlineovercut. The main aim was to identify the electrode which could enhance the newlineproduction of quality micro-holes and to have a significant contribution for newlinemodern industrial requirements. From the experimental analysis, it was found that gap voltage and newlinecapacitance exert more influence on MRR and copper followed by silver newlinetungsten exhibited better MRR. To achieve lower TWR, lower discharge level newlinewas appreciable and tungsten proved to show good performance followed by newlinesilver tungsten. newline