Micro electric discharge milling process performance: An experimental investigation

Micro electric discharge milling (μED-milling) process is gaining lot of interest in the area of microfabrication specifically for hard to machine materials. Any complex shape can be generated with a controlled motion of cylindrical tool in a predefined path similar to conventional micromilling. In this method the material removal mechanism in tool and workpiece is complex and requires a detail study of the process parameters. Parameters such as tool rotation speed, feed rate and aspect ratio (AR) can play a vital role in μED-milling process along with the fundamental parameter such as energy. This research work aims to provide exhaustive study of parameters on material removal rate (MRR) and tool wear rate (TWR) by conducting general factorial experiments. A new method is proposed to measure the volume of material eroded from workpiece and tool with an aid of design software. The experimental result shows that the parameters have individual and combined effect on MRR and TWR. Among the parameters, tool rotation speed has a significant function in flushing away the debris to ensure stable discharge. Detailed surface morphology of the machined features has also been analyzed using scanning electron microscope (SEM). A regression analysis was carried out to establish models for MRR and TWR as a function of process parameters.

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