Abstract—In this growing world of technology, design and manufacturing at the nano and micro level we need the things (product, service, design, technology) more accurate and defect free and on the same guidelines this paper revolve around the same concept of advanced and precision manufacturing. Micro Electro Discharge Machining is a market growing processing technology due to the industrial interest and the increasing number of applications. Micro Electric Discharge Machining appears to be very promising as a future micro-machining technique, since in many areas of applications it offers several advantages, which include higher machining rate, better precision and control, and a wide range of materials that can be machined. This requires advancement of micro manufacturing processes; hence industrial research on micro-machining has become considerably important and widespread. Manufacturing of micro holes by using Micro Electric Discharge Machining (Micro-EDM) is one of the topics towards developing micro manufacturing technology. Consequently, disastrous range of parameters which lead to defect formation inside the hole are found to be due to long pulse duration (>500 ns) together with higher gain (>15). In addition, entrance and exit diameters of through micro-holes are also measured and experimental data are discussed. Conclusively over-travel of tool electrode or secondary machining with a new electrode is recommended to obtain straighter walls and fine surface in micro-holes. Aspect ratios above 15 are obtained easily by using tool electrode with a diameter equal to or less than 75 m in blind holes. The topic is investigated experimentally and extensively in this work.

Index Terms—In this growing world of technology, design and manufacturing at the nano and micro level we need the things (product, service, design, technology) more accurate and defect free and on the same guidelines this paper revolve around the same concept of advanced and precision manufacturing. Micro Electro Discharge Machining is a market growing processing technology due to the industrial interest and the increasing number of applications. Micro Electric Discharge Machining appears to be very promising as a future micro-machining technique, since in many areas of applications it offers several advantages, which include higher machining rate, better precision and control, and a wide range of materials that can be machined. This requires advancement of micro manufacturing processes; hence industrial research on micro-machining has become considerably important and widespread. Manufacturing of micro holes by using Micro Electric Discharge Machining (Micro-EDM) is one of the topics towards developing micro manufacturing technology. Consequently, disastrous range of parameters which lead to defect formation inside the hole are found to be due to long pulse duration (>500 ns) together with higher gain (>15). In addition, entrance and exit diameters of through micro-holes are also measured and experimental data are discussed. Conclusively over-travel of tool electrode or secondary machining with a new electrode is recommended to obtain straighter walls and fine surface in micro-holes. Aspect ratios above 15 are obtained easily by using tool electrode with a diameter equal to or less than 75 m in blind holes. The topic is investigated experimentally and extensively in this work.

Cite: Pankaj Agrawal, Ashish Manoria, Richa Thakur, and Hemant Jain, " Advancement in Micro-Manufacturing Using MEDM and Its Applications," International Journal of Mechanical Engineering and Robotics Research, Vol.1, No. 2, pp. 121-128, July 2012.