Improving the machining performance characteristics of the µEDM drilling process by the online cryogenic cooling approach

Abstract

ABSTRACTProductivity and surface quality would significantly affect the performance of the micro electrical discharge machining process (µEDM). Thus, the machining performance would be enhanced by improving the material removal rate (MRR) and surface quality. In this investigation, cryogenic LN2 cooling was introduced to the conventional µEDM setup for developing an innovative process of cryogenically cooled µEDM process (CµEDM). The favorable outcomes of this process were estimated by selecting discharge current (Ip) and pulse on duration (Ton) for determining the effects of the machining performance including MRR and surface integrity. Surface quality was also analyzed by microstructural analysis and a scanning electron microscope (SEM) for evaluating the effects of the cryogenically cooled µEDM process. The experimental result shows 54–62% improvement in MRR and 22–36% improvement in average roughness values. Hence, it is suggested that cryogenically cooled µEDM facilitates improvement in productivity and surface quality.