In the present work the scope of using micro-electro discharge machining (micro-EDM) technique to generate metalnanoparticles is studied and thermal conductivity of the fluid with particles generated using micro-EDM is characterized. In the experiment, aluminum workpiece is machined with an aluminum tool electrode in deionized water. 40 to 96 V is applied for machining with pulse-on duration being varied between 10 and 100 microseconds. The particle count analysis reveals that low voltage and high pulse-on duration favors formation of smaller sized particles, as predicted by the developed model. A thermal conductivity measurements show 4% rise in thermal conductivity with the sample (0.004% by wt. in deionized water) produced by micro-EDM setup. © 2010 Copyright SPIE - The International Society for Optical Engineering.

Nilesh Jayanthilal Vasa

Department of Engineering Design

Makaram Singaperumal

A-thermal

ALUMINUM TOOLS

Developed model

ELECTRO DISCHARGE MACHINING

Low voltages

METAL OXIDE NANOPARTICLES

MICRO EDM

NANO-FLUID

PARTICLE COUNT ANALYSIS

Particle generation

Work pieces

Aluminum

Composite micromechanics

Deionized water

Electric dipole moments

Electric discharge machining

Metallic compounds

Microanalysis

Microfabrication

Nanofluidics

Nanoparticles

Thermal conductivity

Thermal conductivity of liquids

Thermoanalysis

Micromachining

IIT Madras is a public technical and research university located in Chennai, Tamil Nadu. Founded in 1959, it is recognised as an Institute of National Importance.

IIT Madras has been ranked as the top engineering institute in India for four years in a row by the National Institutional Ranking Framework of the MHRD

It currently offers undergraduate, postgraduate and research degrees across 16 disciplines in Engineering, Sciences, Humanities and Management. About 596 faculty belonging to science and engineering departments and centres of the Institute are engaged in teaching, research and industrial consultancy.

IIT Madras

Investigation on particle generation by micro-electro discharge machining

Proceedings of SPIE - The International Society for Optical Engineering

Micro-Electro Discharge Machining (Micro-EDM) is a prominent non-conventional machining process. In this process, material removal takes place due to the melting and evaporation of electrode materials. The process gained a lot of research interest due to its ample potential in machining metallic materials and simple construction. In this paper, a thermal model has been developed to study the single spark material removal in Micro-EDM process. Single spark material removal study provides the significant information about optimization of the input parameters such as pulsed DC voltage, input current, spark duration, material removal rate of the electrodes, and area of heat distribution on the workpiece. ANSYS multiphysics is used to study the thermal analysis to determine the temperature and heat flux distribution on the workpiece. Silver material is used for both the electrodes. To validate the model, experiments were designed and conducted on tailor-made Micro-EDM setup. From the simulation study, it was found that for the pulse-on time (spark duration) of 40 µs, the material removed for single per spark was 7.53 ng per spark and the maximum heat flux obtained was 2614.2 × 108 W/m2. Simulation results were compared with the actual machined results. Crater profile was analyzed by Veeco Wyko NT1100 non-contact surface profilometer. The material removed by the single spark is obtained up to 8.16 ng. There was 8% error variation between simulation and experimental study. This may be due to assumptions made during simulation study and the presence of elemental impurities. © 2019, Springer Nature Singapore Pte Ltd.

Lecture Notes in Mechanical Engineering

Finite Element Modeling of Single Spark Material Removal and Heat Flux Distribution in Micro-Electro Discharge Machining Process

Materials Letters

A room temperature process for making Mn2O3 nano-particles and γ-MnOOH nano-rods

Journal of Physics D: Applied Physics

Electro-thermal modelling of anode and cathode in micro-EDM

Wear

Experimental analysis of tribological properties of lubricating oils with nanoparticle additives

Journal of Heat Transfer

Heat Conduction in Nanofluid Suspensions

Wuhan University Journal of Natural Sciences

One step ball-milling synthesis of LiFePO4 nanoparticles as the cathode material of Li-ion batteries

Journal	Proceedings of SPIE - The International Society for Optical Engineering
ISSN	0277786X
Open Access	No