Modelling of Micro Electro Discharge Machining in Aerospace Material

Abstract

In this growing world of technology, design and manufacturing at the nano and micro level we need the things (product, service, design, technology) more accurate and defect free and on the same guidelines my thesis revolve around the same concept of advanced and precision manufacturing. Micro-manufacturing are extensively used for precision manufacturing with ease and error free. Present thesis work involve the use of multipurpose micro machine tool to do micro-EDM hole production on copper workpiece by using Micro-electric discharge machining, Micro-electric discharge machining is one of the advanced and precision manufacturing technology which deals with the micro manufacturing. It is used inproducts of aerospace, automobile and biomedical science industries. It can produce very accurate shapes with very small burrs much smaller than those produced by drilling and energy-beam processing. These parts do not need after-treatment processing such as deburring. It is essential for materials used in fuel nozzles, micro sensors, micro capsules, micro motors micro surgical instruments, micro robots, micro turbine and micro-moulds to resist wear, high temperature and high pressure micro manufacturing parts are widely used in the field of high performance micro machining technology. It can easily work on the hardest known substances with great ease and accuracy. It is also gaining popularity as a new alternative method to fabricate micro structures as it has low set up cost, high accuracy and large design freedom. It can fabricate three dimensional structures with great ease compared to etching or other methods with high aspect ratio. In the present investigation optimization of micro EDM has been carried by considering process parameters like voltage, current and pulse-on time and responses overcut, machining time, circularity error and burr size using L4 orthogonal array and design has been optimized by grey based taguchi method. FEA modelling of micro EDM process has also been carried out to predict the MRR and residual stress for single discharge. Multi-discharge MRR modelling has also been carried out for the micro EDM process and results are verified with the experimental investigation. Effects of different process parameters have also been studied.