Coating on MS with Reversible Experimental Technique on EDM

Anilkumar V. Borakhade

Abstract: This study investigates a novel micromachining method for fabricating micro - metal structures utilizing micro - reversible electrical discharge machining (EDM). The approach combines the deposition and selective removal processes within a micro - EDM system, enabling the ability to deposit or remove metal material using the same machining setup. The research begins by analyzing the process conditions for micro - EDM deposition based on the discharge mechanism. Experimental investigations were conducted using brass and steel materials as tool electrodes, resulting in the successful deposition of micro - cylinders with a diameter of 200?m and a height - to - diameter ratio exceeding 5 on a high - speed steel surface. The process was easily transformed from deposition to selective removal by adjusting the process conditions. Various removal strategies, including micro - EDM drilling and micro - EDM milling, were employed during the machining procedure. Successful drilling of micro - holes with an 80?m diameter in the radial direction of the deposited micro - steel cylinder was achieved. Additionally, micro - EDM milling was employed to fabricate a brass square column measuring 70?m on each side and 750?m in height, as well as a micro - cylinder with a diameter of 135?m and a height of 1445?m. Subsequently, the characteristics of the deposited material were analyzed. Results indicate that the material composition of the deposited micro - cylinder closely resembles that of the tool electrode, with a formed metallurgical bonding at the interface. Moreover, the steel deposited material exhibited a Vickers - hardness of 454Hv, surpassing the hardness of the raw steel electrode at 200Hv. The proposed micro - reversible electrical discharge machining method demonstrates promising capabilities for precise fabrication of micro - metal structures, offering both deposition and selective removal functionalities in a single machining system.

Keywords: Coating, EDM

Edition: Volume 12 Issue 6, June 2023,

Pages: 2194 - 2196