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Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes—Taguchi approach |
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| Authors: | Gunawan Setia Prihandana Muslim Mahardika M Hamdi YS Wong Kimiyuki Mitsui |
| Affiliation: | 1. Department of Engineering Design and Manufacture, University of Malaya, Lembah Pantai, Kuala Lumpur 50603, Malaysia;2. School of Integrated Design Engineering, Keio University, 3-14-1 Hiyoshi, Kohoku-ku, Yokohama 223-8522, Japan;3. Department of Mechanical Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260, Singapore;4. Department of Mechanical Engineering, Keio University, 3-14-1 Hiyoshi, Kohoku-ku, Yokohama 223-8522, Japan;1. School of Manufacturing Science and Engineering, Sichuan University, Chengdu 610065, China;2. School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney 2052, Australia;1. Faculty of Engineering of Bilbao, University of the Basque Country, Alameda de Urquijo s/n, 48013 Bilbao, Spain;2. Faculty of Technical Engineering of Bilbao, University of the Basque Country, Paseo Rafael Moreno “Pitxitxi” 3, 48013 Bilbao, Spain |
| Abstract: | Solutions are needed for increasing the material removal rate without degrading surface quality in micro-electrical discharge machining (μ-EDM). This paper presents a new method that consists of suspending micro-MoS2 powder in dielectric fluid and using ultrasonic vibration during μ-EDM processes. The Taguchi method is adopted to ascertain the optimal process parameters to increase the material removal rate of dielectric fluid containing micro-powder in μ-EDM using a L18 orthogonal array. Pareto analysis of variance is employed to analyze the four machining process parameters: ultrasonic vibration of the dielectric fluid, concentration of micro-powder, tool electrode materials, and workpiece materials. The results show that the introduction of MoS2 micro-powder in dielectric fluid and using ultrasonic vibration significantly increase the material removal rate and improves surface quality by providing a flat surface free of black carbon spots. |
| Keywords: | Micro-electric discharge machining Micro-powder suspended in dielectric fluid Taguchi method Material removal rate Ultrasonic vibration of dielectric fluid |
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