Investigation of tool wear in alumina micromachining by multi-tip ECDM

Experimental analysis of tool wear in alumina micromachining by multi-tip Electrochemical Discharge Machining (ECDM) technique is reported. Multi-tip electrodes having a tip size 300 µm and length 10 mm are created stainless steel wire-EDM. Experiments conducted at different feed rates, i.e., 0.25 µm/s, 0.50 0.75 µm/s. Tool 3 × array electrode categorized into three zones, outer-most tip, outer-middle wear, central-tip. The experimental results reveal that the tips worn out rapidly compared to other due localization higher current density easier availability fresh electrolytes. severe slower rate prolonged exposure temperature generated during ECDM. However, (≥0.50 µm/s), tool-tips physical contact with substrate. central has sideways bending beyond travel 400 would have led breakage thin useful understanding pattern ECDM process used non-conductive materials.