Cutting Parameter Optimization Of Hybrid Micro-Rotary Wire Electrical Discharge For Surgical Device Fabrication

Kasim, Dr. Mohd Shahir and Saedon, Dr. Juri and Mohd Ariffin, Prof. Dr. Khairol Anuar and Md. Ali, Prof. Madya Dr. Mohd Amran and Raja Abdullah, Prof. Madya Dr. Raja Izamshah and Anand, Prof. Madya Dr. T. Joseph Sahaya and Sulaiman, Dr. Mohd Amri and Abu Bakar, Ir. Dr. Mohd Hadzley and Abdul Aziz, Dr. Mohd Sanusi and Mohd Zakaria, Muhammad Akmal and Harun, Nurul Hatiqah (2017) Cutting Parameter Optimization Of Hybrid Micro-Rotary Wire Electrical Discharge For Surgical Device Fabrication. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Micromachining is the latest technology in manufacturing of miniaturized parts and components.Taking advantage of high accuracy of advance machining process, miniaturization of industrial products has been demanded for domestic application.Thus,micromachining is expected to play an increasingly important role in today's manufacturing technology.The growth of demand for micro-products and components has been rapidly increased in medicine,biotechnology and avionic products.The cutting parameter is crucial to be controlled properly as to minimize the defect during cutting process.For example, the overhang ratio that associate with workpiece diameter and length must be controlled so that the rigidity is maintained during cutting process.In producing micro shaft by micro-turning process,the common method is by using parallel-cut that is difficult to maintain accuracy,the shaft tends to deflect because the inappropriate overhang ratio due to reducing of material diameter.Therefore,the alternative strategy namely step-cutting approach was introduced for non-traditional machining process.There is another method to fabricate the micro cylindrical components by combining a rotary table to wire electrical discharge machine.Micro-achining using rotary EDM has advantage of non-contact and precision process.Small dynamically balanced parts that require a high surface quality are cut accurately with high-speed erosive turning because the absence of tool pressure allows for small diameters.Notches or other flat features can also be cut in the same setup configuration. Rotational EDM is the perfect solution for cutting delicate parts since there are no cutting forces involved. It is even more advantageous when dealing with difficult-to-cut materials,such as Titanium (Ti-6Al-4V) and Inconel 718.In micro-rotary wire electrical discharge machining,there are additional parameters which are spindle rotational speed that has potential to affect the results of surface finish,material removal rate and roundness.Therefore,the objective this research is to investigate these parameters and identity the most appropriate combination as to improve surface integrity of machining part.

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