ABSTRACT

Reverse micro electro-discharge machining (RµEDM) is a promising and cost-effective technology for fabricating unconventional shaped single and arrayed micro-pins of high aspect ratio. However, dimensional inaccuracies, poor surface finish and long machining time are of great concern. An experiment-based detailed investigation of process parameters for analyzing various machining responses has been performed in this article. Taguchi’s L16 orthogonal array design of experiments has been used to frame out the experimental runs. Discharge voltage, capacitance and feed rate have been considered as process parameters whereas, material removal rate, taper root angle, surface roughness and machining time as responses for the fabrication of a single micro-pin. Additionally, the feasibility of a novel high-pressure suction flushing technology implemented for RµEDM has been demonstrated. The performance of this technology is verified for better surface quality and lesser machining time. It is observed that by using the proposed suction technology, along with the suitable parametric settings, the micromachining time significantly improved (~20%) while fabricating an arrayed micro-pins in elliptical cross-sections profile.

摘要

反向微放电加工 (RµEDM) 是一种很有前景且具有成本效益的技术，用于制造具有高纵横比的非常规形状的单个和阵列微针。然而，尺寸不准确、表面光洁度差和加工时间长是人们非常关注的问题。本文对用于分析各种加工响应的工艺参数进行了基于实验的详细研究。Taguchi 的 L16 正交阵列实验设计已用于构建实验运行。放电电压、电容和进给率被认为是工艺参数，而材料去除率、锥根角、表面粗糙度和加工时间作为制造单个微针的响应。此外，已经证明了为 RµEDM 实施的新型高压抽吸冲洗技术的可行性。该技术的性能已得到验证，可实现更好的表面质量和更短的加工时间。据观察，通过使用所提出的抽吸技术以及合适的参数设置，在制造椭圆截面轮廓的阵列微针时，微加工时间显着改善（~20%）。