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<p>Micromachining, particularly die-sink electrodischarge machining (EDM), stands as a pivotal process in precision manufacturing. However, the realm of non-conventional techniques remains relatively unexplored compared to conventional methods like milling and drilling. This study delves into the realm of non-conventional micromachining, spotlighting the implementation of additively manufactured components. Specifically, it focuses on micro-EDM utilizing a metallic additive manufactured tool (SS316L) fabricated through laser powder bed fusion (LPBF) technology, employed alongside workpieces crafted through conventional means. The process involves EDM drilling of 0.5-mm-deep holes in aluminum, copper, brass, and mild steel workpieces using a cylindrical tool with a 1&#xa0;mm diameter. Parametric optimization is conducted, varying input parameters such as voltage (V), pulse on time (μs), and pulse off time (μs) across three levels to construct an L9 Taguchi array. The primary objective encompasses achieving a high material removal rate (MRR) while minimizing tool wear rate (TWR), alongside investigating the influence of these input parameters on overcut. This study not only establishes a foundational understanding but also addresses the scarcity of research integrating micro-EDM with 3D printed tools. By discerning the optimal set of input parameters and their impact on process performance, this research endeavors to advance the comprehension and applicability of additively manufactured materials in micromachining, thereby fostering precision manufacturing in advanced materials.</p>

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Micromachining (EDM) Using 3D Printed Tool

  • 期刊论文

  • 发表日期：

    2026年1月14日

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  • Bhavya Kotak,
  • Abhishek Kumar,
  • Vishvesh Badheka

摘要

Micromachining, particularly die-sink electrodischarge machining (EDM), stands as a pivotal process in precision manufacturing. However, the realm of non-conventional techniques remains relatively unexplored compared to conventional methods like milling and drilling. This study delves into the realm of non-conventional micromachining, spotlighting the implementation of additively manufactured components. Specifically, it focuses on micro-EDM utilizing a metallic additive manufactured tool (SS316L) fabricated through laser powder bed fusion (LPBF) technology, employed alongside workpieces crafted through conventional means. The process involves EDM drilling of 0.5-mm-deep holes in aluminum, copper, brass, and mild steel workpieces using a cylindrical tool with a 1 mm diameter. Parametric optimization is conducted, varying input parameters such as voltage (V), pulse on time (μs), and pulse off time (μs) across three levels to construct an L9 Taguchi array. The primary objective encompasses achieving a high material removal rate (MRR) while minimizing tool wear rate (TWR), alongside investigating the influence of these input parameters on overcut. This study not only establishes a foundational understanding but also addresses the scarcity of research integrating micro-EDM with 3D printed tools. By discerning the optimal set of input parameters and their impact on process performance, this research endeavors to advance the comprehension and applicability of additively manufactured materials in micromachining, thereby fostering precision manufacturing in advanced materials.