Abstract
Abstract In micro-EDM drilling, due to substantial wear of the tool and unpredictable influences of the process parameters, it is often difficult to ensure the hole quality and enhance the process productivity when machining small through-holes. This research investigated the micro-EDM process for drilling small through-holes on Ti-6Al-4 V using brass tubular electrodes. Taguchi L32 orthogonal array design was used to investigate the effects of different combinations of process parameters, and Gray relational analysis was proposed to select the optimal setting. The machining performance has been evaluated in terms of material removal rate, tool wear rate, and surface roughness. The completion of the drilling processes once the tool breaks through has been detected through identification of different discharge conditions by means of real-time monitoring of the electrical signals. Preliminary experimental results have shown that monitoring of the electrical signals can be used to effectively detect the breakthrough and prevent the machining of a surface situated below the hole exit.
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