Micro ED milling is an excellent microfabrication technique for machining of complex micro shapes and microstructures. It has the potential to machine any electrically conductive material irrespective of its mechanical characteristics. In this work, the effect of different nanopowders, namely graphite (Gr) and carbon nano tubes (CNT) powder and their concentration on response indicators while machining of Ti-6Al-4V under different discharge energy regions is investigated. The surface texture of the milled surface with plain dielectric and nanopowder mixed dielectrics have also analyzed. The highest MRR was achieved with CNT powder as compared to graphite powder due to its high electrical conductivity. The mixing of nanopowder particles in dielectric resulted in a smoother surface than plain dielectric due to the uniform distribution of heat energy over the machining region. It was found the thickness of the recast layer is reduced due to the addition of nanopowders in the dielectric fluid. The maximium recast layer thickness (4.14 μm) is observed with the plain dielectric at high discharge energy. The thickness of the recast layer seems to be minimium when higher-order powder concentration is used. Nanopowder mixed dielectrics offered a better material removal rate than plain dielectric at the cost of overcutting. Material migration is lesser in the case of nanopowder mixed dielectrics due to an increase in number of discharges per second. The material migration is reduced by 54% and 31%, due to the addition of CNT and Gr powders in dielectric respectively. Tool life gets improved with nanopowders mixed dielectric due to the reduction of unwanted discharges and embdement of powder particles on tool material.

微电火花铣削是一种出色的微细加工技术，用于加工复杂的微观形状和微观结构。无论其机械特性如何，它都有可能加工任何导电材料。在这项工作中，研究了不同纳米粉末，即石墨 (Gr) 和碳纳米管 (CNT) 粉末及其浓度对不同放电能量区域下加工 Ti-6Al-4V 时响应指标的影响。还分析了具有普通电介质和纳米粉末混合电介质的铣削表面的表面纹理。由于其高导电性，与石墨粉末相比，CNT 粉末实现了最高的 MRR。由于热能在加工区域上的均匀分布，纳米粉末颗粒在电介质中的混合导致比普通电介质更光滑的表面。发现重铸层的厚度由于在介电流体中添加纳米粉末而减小。最大重铸层厚度 (4.14μ m) 在高放电能量下用普通电介质观察到。当使用更高阶的粉末浓度时，重铸层的厚度似乎是最小的。纳米粉体混合电介质比普通电介质提供了更好的材料去除率，但代价是过度切割。由于每秒放电次数的增加，在纳米粉末混合电介质的情况下，材料迁移较少。由于分别在电介质中添加了 CNT 和 Gr 粉末，材料迁移减少了 54% 和 31%。由于减少了不需要的放电和粉末颗粒在工具材料上的嵌入，纳米粉末混合电介质可以提高工具寿命。