Analyzing laminated electrode(s) performance for the EDM of microchannel(s) in Al(6061).

Aluminum alloys specifically Al6061 have widespread applications; however, its processing is challenging via conventional means due to chip adhesion and burr formation. Moreover, it is difficult to attain dimensional accuracy of the machined profile in the said alloy especially if the size of the machined profile is in a micron which is a common requirement in case of microchannels' formation. Microchannels have wide applications in biomedical, chemical, and electronics industry. Therefore, in this study, the potential of EDM is comprehensively investigated for machining of dimensionally consistent microchannel(s) in Al6061. Single, double, and triple microchannel(s) are produced using laminated brass electrode(s) employing Taguchi (L18) design. The dimensional error was measured for each of the produced microchannel(s) using coordinate measuring machine (CMM). It has been revealed that number of channels and electrode thickness is the significant factors contributing 84.9% and 4.7%, respectively, to the depth deviation (Dd). Dd increases with increase in number of channels and electrode thickness. Electrode thickness is the most influential parameter (85.4%) affecting width deviation of microchannel(s). Width deviation experiences, a drop when a thicker electrode is engaged. The thinnest electrode (0.2 mm) has provided the highest value of arc radius which translates to flatter base of channel. [ABSTRACT FROM AUTHOR]