Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes-Taguchi approach

Solutions are needed for increasing the material removal rate without degrading surface quality in micro-electrical discharge machining (V-EDM). This paper presents a new method that consists of suspending micro-MoS(2) powder in dielectric fluid and using ultrasonic vibration during mu-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 mu-EDM using a L(18) 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 MoS(2) 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. (C) 2008 Elsevier Ltd. All rights reserved.