Micro Modeling and Machining of Aerospace Material with Electro Discharge Machining

Abstract

Sparks created between an anode and a cathode submerged in a dielectric media are used to melt the material and remove it off the work surface in a technique known as micro electrical discharge machining (Micro EDM). Current scenarios necessitate the production of micro products with the desired precision and accuracy for use in fields as diverse as biomedicine, nuclear defence, transportation, and space exploration; consequently, my thesis is centred on this very idea of advanced and precision manufacturing. Aerospace components have been machined using EDM for decades, but the heated nature of the technique has long raised concerns about the safety and dependability of the finished products. Researchers have sought to model the EDM process in recent years; one such technique is to model it using thermal analysis. Milling straight, circular, and spiral microchannels, as well as other micro characteristics required in MEMS devices, is required. When it comes to creating some of the 3D microstructure, micro EDM is superior to microfabrication methods. In this study, we optimized micro EDM using the L9 orthogonal array and the grey-based Taguchi method, taking into account process parameters such as the response of the machining time, error with circularity, layer thickness, current (A), pulse on time, voltage (v) etc. The finite element procedure for the Micro EDM process has been effectively studied to estimate the metal removal rate (MRR) along with the residual stress for the single discharge.