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Experimental Investigation & Taguchi Optimization using Micro-EDM




Grey Taguchi Method, Micro-EDM, Metal Removal Rate Analysis of Variance, MINITAB Surface Roughness


There is a huge demand in the production of microstructures by a non-traditional method which is known as Micro-Electrical discharge machining (Micro-EDM). Micro-EDM process is based on the thermoelectric energy between the workpiece and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of 50 μm -100 μm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges occur in a small gap time removes the unwanted material from the parent metal through the process of melting and vaporization. The characteristics parameters of material removal rate, tool wear ratio and the tool wear rate that are essential in the Micro-EDM process. This procedure deals with optimization of micro- Electrical Discharge Machining (micro-EDM) drilling process using Taguchi method. Micro-EDM is a thermal process that utilizes spark discharges to erode a conductive material. The objective is to study the effect of independent variable to accuracy of micro EDM drilling process and to optimize it by using Taguchi method. Taguchi Method is used to find the optimal drilling parameters for hole diameter in drilling operation. The orthogonal array, the signal-to-noise ratio, and analysis of variance are employed to study the performance characteristics in drilling operations. Three operational parameters namely, pulse off time, peak current, and servo standard voltage, are optimized with considerations of hole diameter. It is found that Taguchi’s robust orthogonal array design method is suitable to analyze the hole diameter problem. Also parameter design of Taguchi method provides a simple, systematic and efficient methodology for the optimization of drilling process. The result concluded that use of greater pulse off time, greater peak current and medium servo standard voltage give the better hole diameter for the specific test range. The results also significantly reduce the cost and time market and improve product reliability and customer confidence. There are several suggestions that could be implanted as to improve results and obtained more accurate finding. In addition, further study could consider more factor such as pulse on time, material removal rate (MRR), coolants and etc in the research to see how the factors would affect hole diameter.

Other Details

Paper ID: IJSRDV5I40242
Published in: Volume : 5, Issue : 4
Publication Date: 01/07/2017
Page(s): 299-303

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