Micro-feature fabrication on external cylindrical surface by centreless electric discharge grinding

Abstract

No research initiative is identified concerning to the development of EDG as feature fabrication technique along curved surfaces using disc electrode. Challenges for micro-features fabrication along external cylindrical surfaces of thin fragile parts still remain unaddressed. The current research was carried out on innovative EDM setup using newly developed centreless grinding attachment with run out accuracy of less than 0.008 mm, to make precise controlled grooving pattern on Inconel 600 tubular part using thin graphite disc wheels. Among the various process controlling variables, peak current and open gap voltage were selected for present study to investigate their effect on MRR, surface roughness and run out accuracy. Peak current and open gap voltage significantly influence MRR and surface roughness. It was found that run out accuracy is not a function of electrical parameters and depends on running accuracy of supporting and driving arrangement. Increase of peak current significantly increases MRR and surface roughness whereas both the responses have inverse effect for increase of gap voltage. Rotationally symmetric feature fabrication by hybrid centreless electric discharge texturing by grinding does not affect run out accuracies of the component.