Fabrication of Complex Micro Channels by Micro Electric Discharge Milling (µ-ED Milling)

2013 ◽  
Author(s):  
Vaibhav Shukla ◽  
Syed Nadeem Akhtar ◽  
S. Kanmani Subbu ◽  
J. Ramkumar
Keyword(s):  
Electric Discharge ◽  
Geometrical Parameters ◽  
Machining Parameters ◽  
Curved Channels ◽  
Micro Channels ◽  
Complex Shapes ◽  
Successful Approach ◽  
Full Factorial Experimental Design ◽  
Optimized Conditions ◽  
Electric Discharge Milling

Micro electric discharge milling (μ-ED milling) is an effective and economic process for the fabrication of micro channels. In the present work, the bulk approach of μ-ED milling is being attempted to make complex shaped micro channels. For a straight channel the bulk approach of μ-ED milling was found to be a successful approach. A tungsten tool of diameter 500 μm was used to fabricate semi-circular micro channels on EN-24 steel. Important machining parameters had earlier been optimized to make straight channels on EN-24 steel by the same method. The effect of geometrical parameters such as radius of curved channel and aspect ratio on MRR and TWR were studied by full factorial experimental design for single pass at optimized machining parameters. Finally complex shapes like T-type and serpentine channels were made by using optimized conditions of straight and curved channels by bulk approach with multiple passes of μ-ED milling.

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

Observation at the Interelectrode Gap of Micro Electric Discharge Milling

2021 ◽  
Author(s):  
Satish Mullya ◽  
Ganesh Karthikeyan ◽  
Ranjit S. Patil ◽  
Rajkumar Patil
Keyword(s):  
Electric Discharge ◽  
Interelectrode Gap ◽  
Electric Discharge Milling

An investigation into performance of electric discharge milling using slotted tools

2020 ◽  
Vol 34 (6) ◽  
pp. 2525-2533
Author(s):  
Satish Mullya ◽  
Ganesh Karthikeyan ◽  
Vaibhav Ganachari
Keyword(s):  
Electric Discharge ◽  
Electric Discharge Milling

scholarly journals Asymmetrical Split-and-Recombine Micromixer with Baffles

Micromachines ◽  
2019 ◽  
Vol 10 (12) ◽  
pp. 844 ◽  
Author(s):  
Wasim Raza ◽  
Kwang-Yong Kim
Keyword(s):  
Reynolds Number ◽  
Geometrical Parameters ◽  
Mixed Species ◽  
Mixing Index ◽  
Number Range ◽  
Mixing Performance ◽  
Curved Channels ◽  
Advection Diffusion Equation ◽  
Advection Diffusion ◽  
Reynolds Number Range

The present work proposes a planar micromixer design comprising hybrid mixing modules of split-and-recombine units and curved channels with radial baffles. The mixing performance was evaluated numerically by solving the continuity and momentum equations along with the advection-diffusion equation in a Reynolds number range of 0.1–80. The variance of the concentration of the mixed species was considered to quantify the mixing index. The micromixer showed far better mixing performance over whole Reynolds number range than an earlier split-and-recombine micromixer. The mixer achieved mixing indices greater than 90% at Re ≥ 20 and a mixing index of 99.8% at Re = 80. The response of the mixing quality to the change of three geometrical parameters was also studied. A mixing index over 80% was achieved within 63% of the full length at Re = 20.

Prediction of optimum electric discharge machining parameters for AA7075-SiC composites

2020 ◽  
Vol 27 ◽  
pp. 1192-1196
Author(s):  
S. Sakthivelu ◽  
P.P. Sethusundaram ◽  
M. Meignanamoorthy ◽  
S. Dinesh Kumar ◽  
C. Chanakyan ◽  
...  
Keyword(s):  
Electric Discharge ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Sic Composites
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