Title: Experimental investigation and optimisation of process parameters in micro-electrical discharge machining

Authors: J. Jerald; S. Kumanan; S.P. Leo Kumar; H.V. Chandrakar

Addresses: Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620015, India ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620015, India ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620015, India ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli-620015, India

Abstract: Micro-electrical discharge machining (micro-EDM) is a promising technology for fabricating micro parts in a variety of materials. It is used in the production of micro motors, surgical instruments, micro robots, micro-moulds, automobile engine parts etc. In this study, the effect of machining parameters during machining of Inconel 600 alloy was investigated and parameters optimisation was carried out by considering multiple performance characteristics using Taguchi method and Grey relational analysis. The process parameters considered in this work are open voltage, capacitance, discharge feed and feed rate for the responses include tool wear rate and material removal rate. Experiments based on L9 orthogonal array was carried out and analysis of variance was performed to analyse the experimental results. The coefficient and grades were determined according to Grey relational analysis. The optimised process parameters leads to lower tool wear rate and higher material removal rate are verified through a confirmation experiment.

Keywords: micro electrical discharge machining; micro EDM; RC circuits; micro holes; Taguchi methods; grey relational analysis; GRA; optimisation; process parameters; electro-discharge machining; micromachining; open voltage; capacitance; discharge feed; feed rate; tool wear; wear rate; material removal rate; MRR; orthogonal arrays; analysis of variance; ANOVA.

DOI: 10.1504/IJMTM.2013.058617

International Journal of Manufacturing Technology and Management, 2013 Vol.27 No.1/2/3, pp.88 - 100

Received: 04 Aug 2012
Accepted: 27 Dec 2012
Published online: 29 Apr 2014 *

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