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TECHNICAL PAPERS

# Modeling of Surface Roughness and the Role of Debris in Micro-EDM

[+] Author and Article Information
M. P. Krishna Kiran

Department of Mechanical Engineering,  Indian Institute of Technology, Bombay Powai, Mumbai,400076, India

Suhas S. Joshi1

Department of Mechanical Engineering,  Indian Institute of Technology, Bombay Powai, Mumbai,400076, Indiassjoshi@iitb.ac.in

1

Corresponding author.

J. Manuf. Sci. Eng 129(2), 265-273 (Aug 29, 2006) (9 pages) doi:10.1115/1.2540683 History: Received January 27, 2006; Revised August 29, 2006

## Abstract

Surface roughness is one of the important quality characteristic of a micromachined component. This paper presents a model to predict surface roughness of micro-EDmachined surfaces. The model is based on the configuration of a single-spark cavity formed as a function of process parameters. Assuming the normal distribution of surface heights, the $μ$ and $σ$$(Rq)$ of the surface profile are evaluated after every spark. The model was further extended to capture the role of debris in micro-EDM in changing electric potential at the micropeaks on the cathode surfaces. The chemical kinetics approach was used to evaluate the change in plasma enthalpy and composition as a result of debris inclusion in the dielectric. The corresponding energy distribution between the electrodes was used to predict configuration of the single-spark cavity and the consequent surface roughness using the earlier surface roughness model. The modeling results were found to agree well with the micro-EDM validation experiments performed without and with the inclusion of artificial debris (iron particles) in the dielectric.

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## Figures

Figure 9

Forces on a debris particle

Figure 1

Normal distribution

Figure 2

Process of spark formation and consumption of surface peaks

Figure 3

Indicating the concept of Pcurr and Pprev

Figure 4

Normal distribution of surface heights before and after erosion

Figure 5

Schematic of spark-eroded hemispherical cavity and its centroid

Figure 6

Comparison of roughness values with the experimental values

Figure 7

Debris particles in the interelectrode gap

Figure 8

Schematic of debris particle in the electrode gap

Figure 10

Surface erosion that occurred at various experimental conditions as listed in Table 1

Figure 11

Comparison of roughness values with the experimental values for various values of Rmelt in micro-EDM

Figure 12

Setup developed for using debris included dielectric: (a) schematic of the setup and (b) experimental setup

Figure 13

Comparison of theoretical and experimental roughness values with the inclusion of debris in micro-EDM

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