Abstract
Electrical Discharge Machining (EDM) is one of the most widely used non-traditional machining processes due to its numerous advantages. Since there is a continuous demand for miniaturized components, micro-EDM became a very popular process. The high temperature of melting and vaporization in the machining zone causes uncontrollable electrode wear to occur in the micro-Electrical discharge machining (micro-EDM) process. In the micro-EDM process, it will make a great impact on dimensional accuracy. In this study, a comparison of micro die sinking and micro Electric Discharge drilling processes has been conducted for the three varying levels of parameters for Voltage, Capacitance, and their effect on the Electrode Wear Rate (EWR) and Surface Roughness (Sa) were studied. Then the parameter that is more strongly influencing the unwanted EWR and Surface Roughness was identified and discussed. The maximum percentage change in surface roughness while micro-EDM die sinking and micro-EDM drilling was found to be 66% and 50%. for the given capacitance also 68% and 49% for the given voltage. Similarly, the highest percentage of EWR occurred while micro-EDM die sinking and micro-EDM drilling has been found at 67% and 65% for the given capacitance also 78% and 52% for the given voltage. The erosion of electrode at the bottom surface has been observed before and after the micro-EDM die-sinking and drilling processes.
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