Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling
This paper investigates the use of Al<sub>2</sub>O<sub>3</sub> nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micr...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-06-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/16/7/725 |
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| author | Sharad Yadav Deepak Agarwal Anuj Kumar Sharma Rabesh Kumar Singh Saurabh Chauhan Shalini Mohanty |
| author_facet | Sharad Yadav Deepak Agarwal Anuj Kumar Sharma Rabesh Kumar Singh Saurabh Chauhan Shalini Mohanty |
| author_sort | Sharad Yadav |
| collection | DOAJ |
| description | This paper investigates the use of Al<sub>2</sub>O<sub>3</sub> nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, MRR, depth, and width. A two-stage nested ANOVA is employed to understand the effect of powder concentration within different capacitance levels. The results show that the powder concentration significantly influences the system’s performance in conjunction with the capacitance. At low (100 pF) and high (1000 pF) capacitance, the addition of Al<sub>2</sub>O<sub>3</sub> nano-powder increases the MRR, depth, and width but decreases TWR up to a concentration of 1.0 g/L. A desirability function analysis (DFA) tool identified the best overall performance from 14 experiments, revealing that 100 pF and 1 g/L yield the optimal outcomes. |
| format | Article |
| id | doaj-art-92a20e357d5f4a61af17da91b22a5ce6 |
| institution | DOAJ |
| issn | 2072-666X |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj-art-92a20e357d5f4a61af17da91b22a5ce62025-08-20T03:08:10ZengMDPI AGMicromachines2072-666X2025-06-0116772510.3390/mi16070725Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-MillingSharad Yadav0Deepak Agarwal1Anuj Kumar Sharma2Rabesh Kumar Singh3Saurabh Chauhan4Shalini Mohanty5Centre for Advanced Studies, Dr. A.P.J. Abdul Kalam Technical University, Lucknow 226031, Uttar Pradesh, IndiaCentre for Advanced Studies, Dr. A.P.J. Abdul Kalam Technical University, Lucknow 226031, Uttar Pradesh, IndiaCentre for Advanced Studies, Dr. A.P.J. Abdul Kalam Technical University, Lucknow 226031, Uttar Pradesh, IndiaMechanical Engineering Department, Madan Mohan Malaviya University of Technology, Gorakhpur 273010, Uttar Pradesh, IndiaApplied Science and Humanities, Rajkiya Engineering College, Kannauj 209732, Uttar Pradesh, IndiaFaculty of Engineering and Sciences, University of Greenwich, Chatham Maritime ME4 4TB, UKThis paper investigates the use of Al<sub>2</sub>O<sub>3</sub> nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, MRR, depth, and width. A two-stage nested ANOVA is employed to understand the effect of powder concentration within different capacitance levels. The results show that the powder concentration significantly influences the system’s performance in conjunction with the capacitance. At low (100 pF) and high (1000 pF) capacitance, the addition of Al<sub>2</sub>O<sub>3</sub> nano-powder increases the MRR, depth, and width but decreases TWR up to a concentration of 1.0 g/L. A desirability function analysis (DFA) tool identified the best overall performance from 14 experiments, revealing that 100 pF and 1 g/L yield the optimal outcomes.https://www.mdpi.com/2072-666X/16/7/725micro-EDMpowder-mixed μ-EDMaluminamicro-millingmicro-channelDFA |
| spellingShingle | Sharad Yadav Deepak Agarwal Anuj Kumar Sharma Rabesh Kumar Singh Saurabh Chauhan Shalini Mohanty Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling Micromachines micro-EDM powder-mixed μ-EDM alumina micro-milling micro-channel DFA |
| title | Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling |
| title_full | Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling |
| title_fullStr | Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling |
| title_full_unstemmed | Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling |
| title_short | Experimental Investigation of Al<sub>2</sub>O<sub>3</sub> Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling |
| title_sort | experimental investigation of al sub 2 sub o sub 3 sub nano powder mixed dielectric in edm assisted micro milling |
| topic | micro-EDM powder-mixed μ-EDM alumina micro-milling micro-channel DFA |
| url | https://www.mdpi.com/2072-666X/16/7/725 |
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