Study the Influences of Various Input Variables on Material Removal Rate During μEDM Machining of Super Alloy Material

To manufacture a product accurately and defect free, both design and manufacturing playing the vital role in micro-level in the present scenario. The present work on the basis of advanced and precision manufacturing. Micro-EDM (electro discharge machining) evaporation and melting are the mechanism of material removal in nonconventional machining process, and there will be no contact between electrode and work piece. Both micro-holes and micro-channels which are essential for micro electro mechanical system (MEMS) devices can be easily machined through micro-machining such as micro-EDM. Micro-EDM is found to be capable of machining any conductive materials regardless of hardness, and both hardened and difficult to machine materials can be easily machined with great ease and accuracy using micro-EDM. The machining of the Inconel-718 was done using micro-EDM with a Copper electrode by using RSM-based BBD methodology. The response surface methodology (RSM) method is used to formulate the experiment layout to analyze the effect of each parameter on the material removal rate (MRR). Various process parameters have been used like current, voltage, pulse on time, pulse off time and gap. From the experimental results, it was observed that MRR was increased with current, pulse on time and gap. Maximum MRR was observed with 6 Amp current.