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On micromachining with a focus on miniature gears by non conventional processes: a status report

Tina Chaudhary Arshad Noor Siddiquee Arindam Kumar Chanda Zahid Akhtar Khan

Archive of Mechanical Engineering | 2018 | vol. 65 | No 1 | 129-169

Keywords WEDM ECM Micro-EDM recast layer micro-gear

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Abstract

Recent developments in automation and technology have revolutionized the way products are made. It is directly seen in the evolution of part miniaturization in the sectors such as aerospace, electronics, biomedicine and medical implants. Micromachining is a promising technology to fulfill the need of miniaturization. A review has been done on the micromachining processes such as micro electric discharge machining (micro-EDM) and wire EDM (WEDM), micro electrochemical machining (micro-ECM). Recent literature were studied and categorized in terms of materials, process parameters, performances, product manufactured, and miniature product generation. Starting with brief introduction to micromachining, classifications and applications, technical aspects of discussions from the literature have been presented on key factors such as parameters and the response variables. Important aspects of recast layer, heat effected zone, micro-hardness, micro cracks, residual stress, etc., have been given. A special focus is given to the status of the research on microgear manufacturing. Comparison has been made between other conventional process suitable for micro-gear manufacturing and WEDM. The miniature gear machined by WEDM shows the defect-free microstructure, better surface finish, thin recast layer and improved gear quality parameters such as profile and pitch. Finally, the research gaps and future research directions have been presented.

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Authors and Affiliations

Tina Chaudhary

Arshad Noor Siddiquee

Arindam Kumar Chanda

Zahid Akhtar Khan

An influence of parameters of micro-electrical discharge machining on wear of tool electrode

Govindan Puthumana

Archive of Mechanical Engineering | 2017 | vol. 64 | No 2 | 149-163 | DOI: 10.1515/meceng-2017-0009

Keywords Micro-EDM tool wear ratio process inputs statistical methods main effects interactions regression analysis

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Abstract

To achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a egression relationship between tool wear ratio and the process inputs has been developed.

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Authors and Affiliations

Govindan Puthumana

Technical University of Denmark, Lyngby, Denmark