Dimensional accuracy and surface quality of micro-channels with low-frequency vibration assistance in micro-electro-discharge milling

Micro-electric discharge milling (mu-ED milling) process has attracted interests of researchers in the area of fabrication of three-dimensional miniaturised features specifically in difficult-to-cut materials. However, significant electrode wear during machining degenerates the accuracy fabricated micro-features. Therefore, in this work, low-frequency workpiece vibration is introduced to assist mu-ED milling to improve the dimensional accuracy of fabricated micro-channels. Difficult-to-cut Inconel 718 superalloy was selected as a workpiece for fabricating straight micro-channels. Initially, the effect of vibration assistance on the mu-ED milling process performance was evaluated in terms of material removal rate and tool wear. Then, the effect of low-frequency workpiece vibrations on dimensional accuracy and surface quality of fabricated micro-channels was investigated using microscopic images. Overall, the low-frequency workpiece vibration assistance found to be effective in enhancing the process performance of mu-ED milling process.

Automated summary

This study introduces low-frequency workpiece vibration assistance to improve the dimensional accuracy and surface quality of fabricated micro-channels in mu-ED milling.