Performance analysis and parametric optimization of micro edm of monel alloy

Abstract

In recent years, the demand for micro structures, micro componentsand minimization of product size is increasing, which ultimately promotes thedevelopment of micro machining technology. One of the unconventionalmachining processes, Micro-EDM offers great potential for processingvarious advanced conductive materials because of its capability to machineany material irrespective of the hardness, very small machining forcesinvolved during machining and its excellent repeatability. Micro EDMperformance is assessed primarily in terms of accuracy, Material RemovalRate (MRR) and tool wear rate. In micro- EDM the process performance isinfluenced by a large number of machine setting parameters and the materialproperties of the workpiece. The determination of suitable operatingconditions is the essence of any manufacturing process, to ensure the qualityof the machined components at reduced cost in order to obtain the bestperformance. Generally selection of process parameters is carried out byrelying heavily on operator experience or crisp technological data provided byEDM machine manufacturers. The information given by the machinemanufacturers is inadequate and also applicable for regular materials. Theoptimum machining parameters for the new materials like advanced tool steel,Titanium alloys, Aluminium alloys, Nickel alloys and metal matrixcomposites have to be found out by experimentation. However, selecting theoptimum machining parameters for the new materials is not an easy task andalso it requires huge time and effort, as the parameter selection does notdepend on the single criterion and multiple factors have to be considered thatmakes the process very critical. Therefore the selection of optimummachining parameters for a new material has been given due importance inthis research. newline