Experimental study of conventional wire electrical discharge machining for microfabrication

Ali, Mohammad Yeakub and Mohammad, Ammar Sami (2008) Experimental study of conventional wire electrical discharge machining for microfabrication. Materials and Manufacturing Processes, 23 (7). pp. 641-645. ISSN 1042-6914

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Abstract

This article discusses the investigation and optimization of the process parameters of conventional wire electrical discharge machining (WEDM) of a copper substrate for microfabrication. The effect of discharge current, pulse-on time, and gap voltage on surface finish were studied. The average surface roughness (R a ) and peak-to-valley height (R t ) were measured with a surface profiler. The surface roughness increased with higher discharge current and gap voltage. With the increase of pulse-on time, the surface roughness decreased. Statistical models were established to predict the surface roughness R a and R t in terms of discharge current, pulse-on time, and gap voltage. Using the optimized parameters, miniaturized spur gears, and plate-shaped hot embossing microtools were fabricated where an average surface roughness of about 1 µ m and dimensional accuracy of 1–2% were achieved.

Item Type:	Article (Journal)
Additional Information:	4751/27095
Uncontrolled Keywords:	Design of experiment; Discharge current; Electrical discharge machining (EDM); Gap voltage; Hot embossing microtool; Micro-EDM; Microfabrication; Microgear; Micromachining; Microreplication; Miniaturization; Modeling of surface roughness; Pulse-on time
Subjects:	T Technology > TJ Mechanical engineering and machinery T Technology > TS Manufactures
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button):	Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering
Depositing User:	Prof. Ir. Dr. Mohammad Yeakub Ali
Date Deposited:	24 Jul 2013 09:05
Last Modified:	24 Jul 2013 09:05
URI:	http://irep.iium.edu.my/id/eprint/27095

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