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<p>The rising utilization of copper in electronic devices, diode switches, and laser systems necessitates a thorough examination of the slitting process for copper sheets. This research study examines the micro-slitting and machinability of a copper sheet having thickness of 100&#xa0;μm through micro-electrical discharge machining (µEDM). A comparative assessment of the performance of two electrodes, copper (Cu) and tungsten carbide (WC), during the machining of microslits in Cu thin sheets using µEDM is also discussed in this research work. According to ANOVA, capacitance and voltage are the most significant process variables. The process is optimized by Overall Evaluation Criteria (OEC). The optimal condition, where all responses are assigned equal weightages (OEC-1), is achieved at a capacitance = 100 pF, voltage = 80&#xa0;V, feed rate (FR) = 10&#xa0;μm/s, and a tool rotating speed (TRS) = 1200&#xa0;rpm. The optimal condition for achieving a balance between machining efficiency and dimensional accuracy is observed at capacitance = 10,000 pF, voltage = 200&#xa0;V, FR = 40&#xa0;μm/s, and TRS = 2800&#xa0;rpm. The average slit widths at the top and bottom sides are 506.01&#xa0;μm and 483.08&#xa0;μm at OEC-1, and 509.28&#xa0;μm and 484.20&#xa0;μm at OEC-2, respectively.</p>

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Machining of micro slit arrays in copper thin sheet using copper and WC tools in micro-EDM and their performance comparison

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Tanmoy Majumder,
  • Promod Kumar Patowari

摘要

The rising utilization of copper in electronic devices, diode switches, and laser systems necessitates a thorough examination of the slitting process for copper sheets. This research study examines the micro-slitting and machinability of a copper sheet having thickness of 100 μm through micro-electrical discharge machining (µEDM). A comparative assessment of the performance of two electrodes, copper (Cu) and tungsten carbide (WC), during the machining of microslits in Cu thin sheets using µEDM is also discussed in this research work. According to ANOVA, capacitance and voltage are the most significant process variables. The process is optimized by Overall Evaluation Criteria (OEC). The optimal condition, where all responses are assigned equal weightages (OEC-1), is achieved at a capacitance = 100 pF, voltage = 80 V, feed rate (FR) = 10 μm/s, and a tool rotating speed (TRS) = 1200 rpm. The optimal condition for achieving a balance between machining efficiency and dimensional accuracy is observed at capacitance = 10,000 pF, voltage = 200 V, FR = 40 μm/s, and TRS = 2800 rpm. The average slit widths at the top and bottom sides are 506.01 μm and 483.08 μm at OEC-1, and 509.28 μm and 484.20 μm at OEC-2, respectively.