Abstract:
Reverse micro electro-discharge machining (RµEDM) is a promising and cost-effective technology for
fabricating unconventional shaped single and arrayed micro-pins of high aspect ratio. However, dimensional inaccuracies, poor surface finish and long machining time are of great concern. An experimentbased detailed investigation of process parameters for analyzing various machining responses has been
performed in this article. Taguchi’s L16 orthogonal array design of experiments has been used to frame
out the experimental runs. Discharge voltage, capacitance and feed rate have been considered as process
parameters whereas, material removal rate, taper root angle, surface roughness and machining time as
responses for the fabrication of a single micro-pin. Additionally, the feasibility of a novel high-pressure
suction flushing technology implemented for RµEDM has been demonstrated. The performance of this
technology is verified for better surface quality and lesser machining time. It is observed that by using the
proposed suction technology, along with the suitable parametric settings, the micromachining time
significantly improved (~20%) while fabricating an arrayed micro-pins in elliptical cross-sections profile.
