Abstract
Micro holes with high aspect ratio in high strength materials are difficult to produce using mechanical micro drilling because of high tool wear, frequent tool breakage and deterioration of hole quality. EDM drilling is most preferred non-contact thermal erosion process for producing micro holes in hard to machine materials. But still there are some challenges for EDM drilling such as high tool wear rate, expansion of hole diameter and taper in drilled hole etc. In present work, an experimental investigation is presented to determine the influence of process parameters on hole diameter expansion and taper rate in drilling micro holes of high aspect ratio. The parameters investigated are discharge current (Ip), pulse-on time (Ton), pulse off time (Toff), electrode material, electrode rotation speed, depth of drilling and electrode diameter while micro drilling in Ti-6Al-7Nb. The diametric expansion and taper rate for Ti-6Al-7Nb are compared with two other high strength materials namely WC-Co and Nimonic-90.
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