A microscopic investigation of machining behavior in μED-milling process

The discussion presented in this work is about evaluation of physical behavior of μED-milling process based on channel shape, form and surface quality. μED-milling process is gaining lot of interest in recent times in micro manufacturing to generate complex shapes. Tool rotation and traverse which are not an inherent part of EDM process become important for μED-milling where it significantly influence the molten metal flow, debris flushing and redeposition. The effect of tool rotation not only disturbs the plasma but also affects the final shape and form of channel. Using scanning electron micrographs of μ-channel at different instant and conditions of machining, the physical nature of the process is understood and the results are presented. This study will provide a better understanding of the working phenomenon of μED-milling process.

► The topic considered for the study is μED-milling process.
► In μED-milling process, the feature shape depends both on tool shape and tool trajectory shape.
► Tool rotation is very essential during machining.
► The study is focused on understanding the working principle of μED-milling process using scanning electron micrographs of channel.
► Channel and tool shape for different conditions are presented.
► Non-Uniform distribution of redeposition on the channel side is observed.
► Milling marks are found on channel base.