50

CHAPTER 3

EXPERIMENTAL INVESTIGATION OF MICRO HOLE DRILLING

USING MICRO-EDM MACHINE

3.1 INTRODUCTION

Most of the published papers on EDM are about the applications with
EDM to meet the needs for industrial applications. Many of them generally
mention about technology, significant machining parameters such as voltage and
current affecting the machining qualities, its machining ability on different type
of materials, MRR of workpiece and wear ratios of tool electrode. The
advantages and disadvantages of micro-EDM as a micromachining technique are
also generally reported in several published papers. The micro-hole machining by
EDM is the dominant subject for this thesis. This is because literature is reviewed
mostly regarding the micro-hole machining parameters, geometry of micro-hole,
aspect ratios, tool wear and material removal with respect to machining time.
However, additional configurations on EDM machine for enhancing machining
quality, 3D micro-parts machining, and comparison of micromachining systems
are also studied, which contribute understanding the EDM phenomena easily.

This chapter investigates the micro-hole drilling process on SS304

using micro-EDM machine (DT110).The machine basically consists of worktable
with X and Y linear scale movement, dielectric supply system, EDM gap control
system, pulsed power supply system, micro-turning attachment, and On-machine
camera. The tool electrode used for the experiments were fabricated in the same
 51

machine by micro-turning process. The experiments were conducted by

considering the parameters such as gap voltage and capacitance. Based on the
experiments MRR, TWR, Overcut and Taper angle were studied.

3.2 EXPERIMENTAL SETUP

3.2.1 Micro-EDM Machine

The micro-EDM machine is energized by a pulse generator which can

be switched to both transistor-type and RC-type. The machine tool has its size of
1.5m (W) 1.1m (D) 1.9m (H), including the controller unit and the dielectric
supply unit. The maximum travel ranges are 210mm (X) 110mm (Y) 110mm
(Z). Each axis has optical linear scale with resolution of 0.1m, and full closed
feedback control and compensation ensures accuracy of up to sub-micron. The
motion controller can execute a program downloaded from the host computer
independently using high speed communication, which creates a very user
friendly environment for the operator on a standard PC. The controller has been
tested to execute more than 300 motion nodes per second.

Figure 3.1 Schematic diagram of the micro-EDM Machine.

 52

At the same time, programs and scheduling can be accessed and

developed to meet the time critical requirement which is a key development area
for micro-machining processes. As for example process parameter sampling can
be done as fast as 20 kHz rate, while still managing other job schedules.
Moreover, it has a multiprocessor-based architecture with UART-based bus
network communication to distribute works between multiple processors. The
response of each axis is important because a fast movement is required for the
gap control during EDM. The servo system was designed to respond to the
reference command within 50 ms. This was found to be excellent for gap control
during EDM process. Figures 3.1 and 3.2 show the schematic diagram and
photograph of the micro-EDM machine. Figure 3.3 shows servo controlled tool
electrode feed system, EDM tank with workpiece and On-machine camera.

Figure 3.2 Photograph of the micro-EDM Machine.

 53

Specification of Micro-EDM Machine

Machine Configuration:
Monolithic natural granite machine base. Gantry type structure
Travel:
X-axis :200mm
Y-axis :100mm
Z-axis :100mm
Table:
Table working surface : 350X200mm
T Slot configuration : 6mm X7(Qty) X25mm (suitable for M5
screws)
Vibration Isolation:
4-point heavy duty passive dampers
Spindle Head:
AC servo motor : 100w (1 to 5,000 rpm)
Optional high speed spindles
Without tool change function : 20,000 rpm or 60,000rpm
With tool change function : 6000 rpm
Power Requirement:
Electrical power supply : 230v, 50 /60Hz
Pneumatic supply : 6 to 7kgf/cm
Machine Size:
Height : 1.9m (2.7m with open door)
Machine space : 1.5m X 1.1m
Machine Accuracy:
Resolution : 0.1m (100nm)
Accuracy : +/-1m /100mm
Repeatability : 1m for all axes
 54

Standard Accessories:
Separate attachment for WEDM and WEDG process
Optional Accessories:
Integrated CCD based camera for on-machine inspection integrated touch
probe.

Figure 3.3 Micro-hole drilling in progress

3.2.2 Workpiece Material

The workpiece material used in this study was Stainless steel of Grade
304. The composition properties of the workpiece material are shown in
Table 3.1.
 55

Table 3.1 Properties of the workpiece materials

Material SS 304
Composition (wt. %) C, 0.08 (max); Mn, 2.00 (max); Si,
1.00 (max); Cr, 18.020.0; Ni, 8.0
10.5; P, 0.045 (max); S, 0.03 (max);
Fe, balance
Density (kg/m3; at 25C) 8,060
Hardness (HRA; at 25C) 56.4 (~92 HRB)
Modulus of elasticity (GPa; at 25C) 193
Melting point (C) 1,450
Thermal conductivity (W/m K) 16.2
1 6
Thermal expansion coefficient (K ; 0 17.210
100C)
Specific heat capacity (J/kg K; 0 500
100C) 720
Electrical resistivity (n m)

3.2.3 Tool Material

The most frequently used tool electrode material in this study was
pure brass. The brass was selected for its high melting point and wear resistance.
The properties of the electrode material are given in Table 3.2.

Table 3.2 Properties of the brass electrode material

Thermal Density Poisson's Specific Heat Melting point
Conductivity (kg/m3) Ratio (J/kg-K) (C)
(W/m-K)
115 8700 0.31 0.378 885-900
 56

3.2.4 Dielectric Fluid

The dielectric fluid used in this study was commercially available

Total FINA ELF EDM 3 oil having relatively high flash point, low pour point,
high auto-ignition temperature and high dielectric strength. The fluid is a clear
mineral oil exhibiting good resistance to oxidation; contains very low aromatic
contents, low volatility, and low pour point creating possibility of outside storage
and low viscosity which ensures that metal chips are evacuated easily. Properties
of EDM oil are shown in Table 3.3.

Table 3.3 Properties of the dielectric fluid

Material Volumetric Viscosity Flash Auto Distillation
mass at at 20oC point ignition range,
15oC (mm2/s) Pensky- temperature IBP/FBP
Martens (oF) (oC)
(oC/ oF)
EDM 813 7.0 134 / 259 470 277/322
oil 3

3.3 EDM ELECTRODE FABRICATION USING A HYBRID OF MICRO-

EDM AND MICRO-TURNING PROCESS

Tool electrode fabrication processes using sacrificial electrode have

their advantages and disadvantages. But, they have few disadvantages in
common. These processes are very difficult for automation and are always error
prone. Most of the cases operator is required to check the fabrication process and
perform manual compensation for the error. Moreover, the electrode fabrication
 57

process takes more than few hours. As for example, to fabricate a 15 m

diameter tool electrode of 0.5mmlength, from a commercially available 0.5mm
diameter tungsten electrode using moving BEDG process, took about 34 hours.
This is well known that tungsten electrode has very little wear against stainless
steel and with this electrode 100 holes could be machined on 50 micron thick SS
304 plate. But, at NUS a new hybrid process for micro-turning has been
developed that can be used to machine very fine electrodes and almost removes
all the disadvantages that sacrificial electrode fabrication processes have.

Figure 3.4 Concept of hybrid process for micro-EDM.

Figure 3.4 illustrates the concept of turning-EDM hybrid machining.

In this hybrid machining process, EDM is carried out using a micro-shaft. An
electrode of required length is fabricated using micro-turning process. Using this
hybrid machining, clamping error can be avoided and deflection of electrode can
be minimized, consequently the accuracy of machining can be improved. When
different diameters of electrode are preferred, turning can significantly reduce the
electrode preparation time as compared to the sacrificial electrode fabrication
methods. This hybrid machining technology also can be used to fabricate a
cylindrical micro component with non-rotational portion such as a key slot or flat
bar by the help of EDM process followed by turning. One of the problems in
 58

machining thin electrode by turning is the deflection of the shaft during

machining. It is always very difficult to achieve straight shaft below 100 m
diameter and in a lot of cases, the tool is either broken or starts to wobble due to
excessive radial cutting force on this micro-shaft.

Figure 3.5 shows the experimental setup for conventional micro-

turning. In this study, for the fabrication of micro shafts, three steps were used:
straight micro-turning, taper micro-turning like pencil sharpener cutting and final
cutting using the modified Poly-Crystalline Diamond (PCD) tool. In the first
approach of straight turning, a small depth is dressed in order to reduce the
wobbling effect of the initial shaft. The amount of materials removal using this
straight turning was kept low in order to avoid the stress concentration effect at
the critical places of varying diameter. Before final cut, another necessary step is
to carve out a tapered surface called the pencil sharpener to provide a strong
support to the shaft with smooth gradient. The tapered surface is generated by
gradual removal material turning along the taper surface by a limited depth of cut
to protect the cutting edge from chipping. There are two reasons for choosing the
taper turning process along the taper surface. Firstly, there is chance of remaining
the cutting marks on the surface in case of stepped taper turning parallel to the
axis, which can act as the point of stretch concentration. Secondly, from the view
point of efficient and fast micro fabrication, turning parallel to the taper surface is
preferable than that of parallel to the workpiece axis (Rahman et al., 2006). The
final fabrication of the micro-shaft is done in a single step up to the tapered tip,
reducing the diameter to the intended diameter. The purpose of creating the tip
prior to the final cut is to allow a shallow depth of cut that prevents possible
chipping of the cutter as well as to reduce the amount of debris that might
interfere with the final turning process. Figure 3.10 shows the on-machine
images obtained during turning showing different steps of micro-turning.
 59

Figure 3.5. Experimental setup for conventional micro-Turning.

Figure 3.6 On-machine images of the shaft at different state of micro-

turning (a) Straight turning, (b) Taper turning and (c) Final shaft
(Rahman M A et. al., 2006)

Figure 3.6 shows one such micro-shaft machined using the

conventional micro-turning method. Figure 3.7 shows the actual cutting with the
commercially available PCD insert, observed under a tool scope. Conventional
PCD insert, designed for finishing light cut, used for -turning has 500 m tool
nose radius (Figure 3.8). A commercially available PCD insert can be modified
to achieve a very sharp cutting edge and thus this makes it possible to achieve
 60

straight shaft with much smaller diameter. Essentially, a sacrificial electrode was
used to perform EDG on the tool edge to achieve a very sharp edged tool.

Figure 3.7 The 500 m diameter shaft fabricated using modified PCD tool
and observed under tool scope.

Figure 3.8. The tool geometry of commercially available PCD inserts for
finishing light cut.

Computer numerical control machines may be the only equipment that

can provide quick and accurate machining operations for workpieces that involve
complex shapes such as three dimensional surfaces. The CNC machine responds
to programmed signals from the machine control unit and manufactures the part.
To achieve micron range dimensions, precise control of the machine as well as
machining parameters such as feed rate, depth of cut and speed is important. The
machining of the micro-electrode requires hundreds of lines of NC code.
 61

Commercially available CAM software is not suitable for fabrication

of the micro-electrode. Windows based programs were written using C++
programming language for generation of the NC codes. Such a NC code
generator facilitates the machining process for taper and cylindrical micro-
turning. The program used for the micro-turning operation is given in Appendix.

3.4 EXPERIMENTAL PROCEDURES

In this study, the experimental plan has two controllable variables

namely gap voltage and capacitance. The range of the gap voltage and
capacitance are selected for quick machining of micro-holes because micro-EDM
process is a slow process. The machining conditions used in this study are listed
in Table 3.4.The workpiece of 200 m thickness with machined micro-holes is
shown in figure 3.9. The program used for the micro-EDM operation is given in
Appendix.

Figure 3.9 SS 304 workpiece of 200 m thickness with machined micro-holes

 62

Table 3.4 Experimental conditions for the micro-EDM drilling

Workpiece Material SS 304 (thickness=200 m)
Tool Electrode Brass (diameter=500 m)
Dielectric fluid Total EDM 3 oil
Pulse generator type RC
Voltage (V) 80, 90,100
Capacitance ( F) 0.01,0.1,0.4
Resistance (k ) Fixed to 1k
Spindle speed (rpm) 100
Feed rate (m/s) 0.5
Polarity Workpiece : +Ve; Tool : -Ve;

The performance of the workpiece material in micro-EDM drilling

process was evaluated by the accuracy of the micro-holes, MRR, and electrode
consumption rate. The accuracy of the micro-holes was evaluated by overcut, and
the taper angle of the fabricated micro-holes. The overcut of the micro-holes was
calculated as the difference between the diameter of the machined holes and the
electrode diameter. Figure 3.10 and 3.11 presents the schematic diagram of
measuring overcut and taper angle of the micro-holes respectively. The MRR
was calculated using the formula given in equation 3.1, which is expressed as
milligrams per minute. As during the EDM process both the workpiece and tool
electrode is eroded simultaneously, TWR is expressed as the ratio of tool weight
loss to the machining time. Equations 3.1- 3.4 (derived from the geometry shown
in Fig. 3.11) were used to calculate the MRR, TWR, overcut, and taper angle,
respectively.
 63

Figure 3.10 Measurement of Overcut

Figure 3.11 Measurement of Taper angle

(3.1)

Where, rentry is the radius at the entrance side, rexit is the radius at exit
side, h is the workpiece thickness, is the density of the workpiece material and
t is the machining time to make a hole at a particular setting.
 64

= (3.2)

Where l is the electrode wear, and Dt is the tool diameter.

The overcut of the micro-holes is measured as:

OC =Dh Dt (3.3)

Where, where Dh is the diameter of the hole after machining, and Dt is the
diameter of the tool.

Table 3.5 Experimental conditions and results

S. Gap Capac- Discharge Machining Tool Entry Exit

No voltage -itance energy Time wear diameter diam-
-ter

V F J min mm m m

1 80 0.01 32 35.46 0.2540 538.2 336.4

2 80 0.1 320 48.28 0.2196 556.8 334.0

3 80 0.4 1280 30.13 0.2375 566.2 273.8

4 90 0.01 40.5 32.86 0.2480 529.0 348.0

5 90 0.1 405 35.40 0.2161 547.6 375.8

6 90 0.4 1620 22.46 0.2116 566.2 366.6

7 100 0.01 50 27.56 0.2404 524.4 338.8

8 100 0.1 500 31.56 0.2126 547.6 399.0

9 100 0.4 2000 22.96 0.2536 570.8 287.6

 65

The taper angle of the micro-holes is measured as:

= tan (3.4)

where is the taper angle, Dentry is the entrance diameter, and Dexit is the exit
diameter of the micro-hole and h is the machined depth. Experimental conditions
and results are presented in Table 3.5.

The performance measures like MRR, TWR, Overcut and Taper Angle are
presented in Table 3.6

Table 3.6 Experimental Results

Expt. MRR TWR OVERCUT TAPER

No ANGLE

Unit (*10-3) mg/min (*10-3) mg/min m in degrees

1 6.95 12.23 38.2 26.77

2 5.31 7.77 56.8 29.12

3 7.71 13.46 66.2 36.17

4 7.51 12.89 29.0 24.35

5 7.71 10.42 47.6 23.24

6 12.44 16.09 66.2 26.52

7 8.68 14.89 24.4 24.89

8 9.06 11.50 47.6 20.38

9 10.52 18.86 70.8 35.30

 66

3.4.1 Experimental measurement and analysis

For measuring dimensions of the micro-holes, the digital optical

microscope was used. To observe the surface quality of micro-holes, a scanning
electron microscope (SEM; JSM-6390, JEOL Ltd) was used, having maximum
values of magnification and accelerating voltage of 3,00,000X and 30 kV,
respectively. An energy-dispersive X-ray (EDX) machine associated with the
SEM was used to investigate the surface properties changes of the workpiece
material after micro-EDM. The SEM-EDS used in this study have the following
technical specifications.

SEM Make : JEOL Model JSM - 6390LV

EDS Make : JEOL Model JED 2300
Resolution : 3 nm (Acc V 30 KV, WD 8 mm, SEI)
: 8 nm (Acc V 3.0 KV, WD 6 mm, SEI)
: 15 nm (Acc V 1.0 KV, WD 6 mm, SEI)
Magnification : 5 to 300, 000 (Both in High and Low
Vacuum Modes)
Image Modes : SEI, BEI
Probe Current : 1 pA to 1mA
High vacuum resolution : 3 nm
Low vacuum resolution : 4 nm
Specimen Stage : 4 nm
Specimen Stage
Type : Eucentric
Tilt : +90
Specimen holder : 10 mm dia
Maximum loadable specimen size : 150 mm dia
 67

3.5 RESULTS AND DISCUSSION

3.5.1 Quality and Accuracy of the Micro-Holes

3.5.1.1 Surface Quality

Since machining is basically a finishing process with specified

dimensions and tolerances, the type of surface that a machining operation
generates and its characteristics are of great importance in manufacturing. In this
study, the surface finish of the micro-holes was evaluated by observation of rim
surface of the micro-holes. The surface at the rim shows whether there is any
debris attached to the rim that deteriorates the surface finish. The SEM images
also provide information about the heat affected surface at the rim. The Entry and
exit microscopic views of micro-holes at different machining conditions are
shown in Figure 3.12.

Figure 3.13 shows the SEM images presenting the surface quality at
the rim of the micro-holes obtained in SS 304 at different discharge energy
settings. It can be observed that the rims of the micro-holes produced in SS 304
have resolidified debris and craters attached to the rims. This effect is more
pronounced at higher discharge energy settings. The reason for this
comparatively poor surface quality of the micro-holes obtained in SS 304 can be
explained by the thermal properties of the materials. Due to low thermal
conductivity of SS 304, the heat generated during machining are not dissipated
rapidly. Thus, the machined surface does not become smooth when it cools, and
there is a tendency at the rim of the micro-holes to be distorted. Moreover, due to
the high ductility and low yield strength, the SS 304 material becomes more
ductile at high temperature during the micro-EDM. Therefore, the surface
finishes deteriorate when it cools again after machining. In addition, the rims of
the micro-holes are more heat-affected, which can cause the micro-hole
expansion and reduce the circularity of the micro-holes. The overcuts of the
micro-holes in SS 304 were also higher, which reduce the dimensional accuracy.
 68

Entry View Exit View

(a) At 100 V, 0.4 F

Entry View Exit View

(b) At 90 V, 0.01 F
Entry View Exit View

(c) At 80 V, 0.1 F
Figure 3.12 Entry and exit microscopic views of micro-holes at different
machining conditions
 69

(a) at 100 V, 0.1 F and 100 V, 0.4 F (b) at 90 V, 0.1 F

(c) at 80 V, 0.4 F and 90 V, 0.01 F (d) at 80 V, 0.1 F

Figure 3.13 SEM Images of micro holes at different machining conditions

 70

(a) (b)

Figure 3.14 Side wall of the machined micro-hole (a) Straight view and (b)
Inclined view

An Energy Dispersive X-ray (EDX) analysis of SS 304 was carried

out to obtain information about the properties and composition changes of
workpiece materials after machining. Figures 3.15 show the EDX analysis of the
workpiece surfaces. The elements present in the surface are clearly indicated by
the peaks corresponding to their energy levels. Moreover, the relative
percentages of different materials after machining are also indicated in Table 3.5.
It can be observed from the analysis that there is a significant change in
composition of elements present in the workpiece after machining. The
percentage of Fe decreases significantly as C increases in the SS 304 after
micro-EDM. This excess amount of carbon came from the dielectric oil and
dislodged from the workpiece in the form of debris and remains resolidified
around the surface of the micro-holes.

Due to high ductility of SS 304, these carbon materials get merged

into the rim of the micro-holes at high temperature during micro-EDM.
Moreover, some percentage of O was found in the EDX analysis of SS 304
 71

after machining. In micro-EDM, sometimes, there is oxidization of debris during

resolidification at the rim, hence, the oxygen content. As the SS 304 has high
ductility, there is more chance of oxidation during the cooling and
resolidification of the material after machining. The mass percentage of different
elements present in the EDX Analysis is shown in Table 3.5

Figure 3.15 EDX spectrum analysis of the machined surface of SS 304 after
micro-EDM.
 72

Table 3.7 EDX spectrum analysis results

Element (keV) Mass% Atom% K

C K 0.277 6.84 25.08 1.1163

Si K 1.739 0.59 0.92 0.326

Cr K 5.411 19.98 16.92 0.7905

Fe K 6.398 69.34 54.65 1

Ni K 7.471 3.25 2.44 1.2976

Total 100 100

3.5.1.2 Overcut

The overcut affects the ability of a material to achieve good

dimensional accuracy and good finishes. The lower and consistent is the size of
the overcut, the more predictable will be the resulting dimension. Figure 3.16
shows the variation of overcut with discharge energy. It has been found that with
the increase of discharge energy, the overcut increases. At lower discharge
energy, smaller amount of material is removed per discharge producing smaller
craters, which in turns results in low overcut. Another reason for the increase in
overcut may be due to the fact that the discharge column formed at high
discharge energy lasts longer than that of at low discharge energy. With a longer
duration of discharge, the electrons released from the negative poles will collide
with the neutral particles in the dielectric fluid, resulting in greater ionization
effect. The greater the number of electrons and ions colliding with the workpiece,
the bigger the micro-hole expansion. However, interesting results of overcut have
been obtained for the micro-holes. This phenomenon can be explained by the
 73

material properties of workpiece material. It can be seen from Table 3.1 that the
thermal expansion coefficient of SS 304 is higher. Therefore, at higher discharge
energy, the overcut increases due to high expansion of the SS 304 materials at
higher temperature.

Moreover, due to high ductility of austenitic steel at high thermal

energy, the discharge column spreads more during micro-EDM drilling. The
effect is more pronounced at deep-hole micro-EDM drilling due to longer
machining period as well as unstable machining conditions like short circuiting
and arcing. As it becomes difficult to remove all the debris from the deep hole
using side flushing, there is more chance of increasing the width of discharge
channel in addition to secondary sparking like short circuiting and arcing during
deep-hole micro-EDM drilling.

75
70
65
60
55
50
45
40
35
30
25
20
25 275 525 775 1025 1275 1525 1775
Discharge Energy ( J)

Figure 3.16 Variation of overcut of micro-holes with discharge energy

 74

3.5.1.3 Taper Angle

Another important characteristic for evaluating the accuracy of the

deep micro-holes is the taper angle of the micro-holes. Figure 3.17 shows the
variation of taper angle of the micro-holes with discharge energy. One of the
reasons of micro-hole taperness in micro-EDM is the corner wear of the tool
electrode. This effect of taperness is more important to consider when machining
deep-holes using micro-EDM. It has been found that the taperness of micro-holes
increases with discharge energy. At high discharge energy, deeper and larger
discharge craters are induced in the workpiece surface, which piles up and causes
unusual secondary sparking. The removal of these larger debris particles from the
machined zone becomes difficult using side flushing.

In most of the cases, short circuiting and arcing occurs on these

deposited debris particles, which is known as secondary sparking. This
phenomenon causes the entrance of the micro-holes to be larger (Liu et al.,
2005). However, when the discharge energy was reduced, the entrance of micro-
holes was not enlarged much, thus reducing the taper angles. Another reason for
taperness in micro-EDM drilling is that the debris produced during micro-EDM
process moves from the bottom of hole and eject out from the top of hole along
the outside of the electrode. This phenomenon will create secondary sparks
between the debris and the work piece, slightly enlarging the hole at the top, thus
making the micro-hole taper. However, it can be observed that up to 500 J, the
taper angle is around 30, which is a good indication of dimensional accuracy.
 75

40.00

35.00

30.00

25.00

20.00

15.00
0 250 500 750 1000 1250 1500 1750 2000
Discharge Energy ( J)

Figure 3.17 Variation of Taper Angle of micro-holes with Discharge Energy

3.5.2 Material Removal Rate

Among all the machinability characteristics of a material, the MRR is

of prime importance. As micro-EDM is more commonly an electro-thermal
machining process, the discharge energy and the electrical and thermal properties
of the workpiece and electrode materials are the main contributing factors
determining the machinability of the materials for micro-EDM. Figure 3.18
presents the variations of MRR of micro-holes with different discharge energy
levels. It has been found that, the MRR increases with the increase of discharge
energies.

During the micro-EDM process, the discharge energy supplied by the

pulse generator is converted into thermal energy in order to raise the temperature
of the workpiece materials to remove materials by means of melting and
evaporation. With the increase of discharge energy, more materials are removed
 76

from the workpiece, thus increasing the MRR. However, some variations of
MRR have been observed with the discharge energy (Figure 3.18). The reasons
for this variation can be explained by two justifications. Firstly, the reason may
be the non-uniform discharge energy during machining that was sometimes
provided by the RC-type pulse generator in lower energy levels (Han et. al,
2004).

In the RC generator, the capacitor stores the electrical energy and

discharges during the machining. When machining starts as soon as the dielectric
breaks down, it discharges the charge stored in the capacitor. Therefore, if the
dielectric breakdown occurs before the capacitor is charged fully, it will not
discharge the maximum energy. Instead, there will be variations in the discharge
energy. Secondly, the gap voltage has an intrinsic relationship with the
magnitude of the working gap, i.e., the distance between the workpiece and
electrode during the spark (Amorim et. al, 2005). Thus, at very low voltage,
though the energy per pulse is low due to a smaller working gap, there is more
possibility of occurring short circuits and arcing.

Moreover, proper flushing may not be possible if the working gap

becomes too small, which in turns decreases the MRR. For example, in 320 J
(80 V, 0.1 F setting), the MRR is lower than that of 50 J (100 V, 0.01 F
setting), though the discharge energy is higher. The reason can be understood
from the parameters setting for two discharge energy levels. At 80 V setting,
though the energy is higher, due to low gap voltage, the MRR is low. In addition
to discharge energy, the thermal and electrical properties of the workpiece
materials have significant influence on MRR. The erosion efficiency is a
contributing factor in determining the MRR, which depends on the thermal and
physical properties of the workpiece materials (Wong et. al., 2003).
 77

14
13
12
11
10
9
8
7
6
5
4
0 250 500 750 1000 1250 1500 1750 2000
Discharge Energy ( J)

Figure 3.18 Variation of MRR of micro-holes with Discharge Energy

3.5.3 Tool Wear Rate

During micro-hole drilling in a material, the tool consumption rate is

an important parameter to consider. In this study, the TWR was calculated to
provide some indication of the electrode consumption. Figure 3.19 shows the
variation of TWR during micro-EDM drilling with different levels of discharge
energy. It has been found that with the increase of discharge energy, the TWR
decreases first then again tend to increase at higher discharge energy. At low
discharge energy, the TWR is higher due to very high machining time. Although
the peak current is lower at low discharge energy, it also prevents sparks from
taking place and thus results in discontinuous discharging, which causes
extensive tool wear (Liao et al, 2004).
 78

On the other hand, at very high discharge energy, the electrode wear
again increases. This is due to the fact that with the increase of discharge energy,
the crater size becomes broad, and more materials are removed from both
workpiece and the electrode. Thus, the amount of debris becomes too great in the
gap and causes difficulty to remove them from the machined area by low
pressured side flushing usually used in micro-EDM. Therefore, arcing occurs due
to establishment of a conductive electrical path between the electrodes. As a
result, more materials are removed from the electrode compared to that of
workpiece, finally resulting more relative tool wear. As the SS 304 materials
become more ductile at high temperature, less amount of electrode materials are
consumed.

Again, there may be deposition of workpiece materials on the tip of

the electrode during machining as it becomes more ductile. It has been reported
in several studies that during electro-discharge machining, there is deposition of
carbon and iron particles on the tool surface facing the workpiece (Soni and
Chakraverti, 1996). This effect is more observable during the EDM of Fe-based
materials, as iron is known as a catalyst for the precipitation of those crystallized
carbon (Mohri et al., 1995). Moreover, it has been reported that there is a
chemical reaction between iron and carbon, which forms the iron carbide,
deposits on the surface of the tool electrode, and decreases the TWR (Marafona,
2007).
 79

20
19
18
17
16
15
14
13
12
11
10
9
8
7
0 250 500 750 1000 1250 1500 1750 2000

Discharge Energy ( J)

Figure 3.19 Variation of TWR of micro-holes with Discharge Energy

3.6 CONCLUDING REMARKS

In this chapter, micro-hole drilling of SS 304 using micro-EDM

drilling has been studied and compared. The machinability was evaluated by
means of MRR, TWR, surface quality, and accuracy of the machined micro-
holes. During the micro-EDM drilling process, the thermal properties of the work
materials were found to have significant influence on the quality and accuracy of
the micro-holes. Moreover, the performance parameters were also found to be
influenced greatly by the thermal and electrical properties of the materials like:
thermal/ electrical conductivity, specific heat capacity, melting point, thermal
expansion coefficient, and behavior of the material at high temperature.
Furthermore, low thermal conductivity, high work hardening tendency, and high
ductility at elevated temperature limit the austenitic steel in drilling quality and
dimensionally accurate micro-holes by making the process unstable and reducing
the MRR. It has been concluded from the study that the time taken for machining
a micro-hole is higher.