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Experimental investigation of single spark μ-EDM using electrodes fabricated with μ-turning process

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Abstract

Micro electrical discharge machining (μ-EDM) stands out as a widely employed non-traditional machining process with diverse applications in microfluidics, electronics, medical, aeronautics, and the automotive industry. This study is dedicated to the exploration of the single spark μ-EDM process utilizing a titanium tool electrode fabricated using a μm-turning process. Intriguingly, it is established that achieving a single spark necessitates a minimum tool diameter of 8 μm. Further, the effect of critical parameters such as voltage and capacitance on material removal rate (MRR), tool wear rate (TWR), as well as the shape and size of the resultant craters is investigated. A 7 μm tool electrode when subjected to a voltage of 100 V and a capacitance of 33 pF manifests a remarkably refined surface finish, demonstrating controlled erosion on the workpiece surface. The study also indicates that MRR and TWR vary exponentially with supplied discharge energy. This comprehensive analysis not only identifies optimal conditions for μm turning during tool fabrication but also elucidates the prerequisites for generating a controlled single spark during workpiece erosion. In essence, the findings presented here contribute valuable insights to the advancement of precision μ-EDM processes.

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Abbreviations

Ff :

Feed force

Fc :

Cutting force

Fd :

Depth force

Fm :

Machining force

Vf :

Feed rate

E:

Discharge energy

≥:

Greater than

ω:

Deflection

F:

Force

σ:

Bending stress

±:

Plus–minus

Ra:

Surface roughness

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Acknowledgements

The authors acknowledge the support provided by the Bhabha Atomic Research Center (BARC) for the BTech project. The authors thank Dr. R. Balasubramaniam, BARC, Mumbai, for the valuable suggestions throughout this project work.

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Authors and Affiliations

  1. Division of Engineering Materials, Department of Industrial and Materials Science, Chalmers University of Technology, Gothenburg, Sweden

    Viney Ghai

  2. Precision Engineering Division, Bhabha Atomic Research Centre (BARC), Anushaktinagar, Mumbai, 400085, India

    Ashwin Rathod & Prabhat Ranjan

  3. Mechanical Engineering Department, Indian Institute of Technology Ropar, Nangal Road, Rupnagar, Punjab, 140001, India

    Viney Ghai & Harpreet Singh

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  1. Viney Ghai
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  4. Harpreet Singh
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Correspondence to Harpreet Singh.

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Ghai, V., Rathod, A., Ranjan, P. et al. Experimental investigation of single spark μ-EDM using electrodes fabricated with μ-turning process. Sādhanā 49, 157 (2024). https://doi.org/10.1007/s12046-024-02522-y

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  • DOI: https://doi.org/10.1007/s12046-024-02522-y

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