Experimental study of conventional wire electrical discharge machining for microfabrication
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 surfa...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
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Taylor and Francis Inc.
2008
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| Subjects: | |
| Online Access: | http://irep.iium.edu.my/27095/ http://irep.iium.edu.my/27095/ http://irep.iium.edu.my/27095/ http://irep.iium.edu.my/27095/1/015_MaMP_2008_23%287%29_641-645.pdf |
| Summary: | 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. |
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