Track: Manufacturing

Abstract

Micro EDM is a versatile process which is effectively used for machining of hard and difficult to cut materials including super alloy. It is a recently developed process for producing micro-parts with dimensions ranging from 50 to 1000 µm. Micro-EDM is a cost-effective machining technology for creating a micro-metal hole which is used in orthopedic implants. In this work Micro EDM experimentations are carried out on the material Ti-6Al-4V. This material finds wide applications in bio medical industries for making dental bone replacement applications. Low frequency Vibrations have been applied to remove the debris from the machining zone. Brass tool of 400 µm diameter is used as a tool electrode material. Micro machining (Micro drilling) is the challenging task because of small size of tool. In this work micro drilling has been attempted with 400 microns tool and thereof tool wear and hole quality have been investigated. The detailed investigation of Material Removal Rate (MRR), Tool Wear Rate (TWR), Surface Roughness (Ra) and Overcut (OC) have been carried out using Micro-structural analysis, Dimensional accuracy, SEM Studies, and EDS analysis. It is found that various parameters have some effects on the hole quality and tool wear. Attempt has been made to find out optimum parameter setting using statistical tools and Design of experiments.