Process performance optimization of μEDM aided with ultrasonic vibration and magnetic force

This study is focused on the investigation of the input parameters of the µEDM on the material removal rate and taper of the microfeature for the machining of SKD-5 die steel using a copper tubular electrode. The Taguchi-based L 18 orthogonal array was adopted for the design of experimentation. An optimal combination of input parameters was achieved using Grey Relational Analysis. The significance of input parameters was analysed using ANOVA. It is found that ultrasonic vibration, magnetic force, tool rotation, energy, and feed rate influence the output response by 25.90%, 17.30%, 11.71%, 32.23%, and 1.92%, respectively. Further, the surface topology of the machined surface shows the least deposition of recast tiny particles under optimal parameters. Identified optimal input process parameters were also tested using a confirmation test, and the predicted combination has good agreement with the findings.