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During the machining of deep hole drilling in industries, Micro-Electrical Discharge machines are frequently exposed to pulse on time and high current, reducing tool life, micro-hole efficiency, machining accuracy, and production rate. As a result of this research, a ground-breaking strategy for overcoming the aforementioned industry problems has been discovered. In this analysis, nickel was coated on the brass electrode with a wall thickness of 2 µm to control the secondary reaction in the machining phase. Current, Voltage, Pulse-on time, and Capacitance parameters were investigated on the micro-coated tool in micro EDM. This article proposed the morphology wear behavior of the tool electrode by the Taguchi (L9 Orthogonal Array) design approach. Micro-holes are drilled with an aspect ratio of 20 on D2 steel using this technique. The coated tool will minimize tool wear and increase the material’s rate of removal and compromises the surface quality according to experimental results. Since a large taper angle was observed in the machining process by the Video Measuring Machine (VMM). The consistency of micro-holes on AISI D2 Steel has suffered, which is analyzed by Optical Microscope. In this research work the size of Crater wear discussed with SEM (Scanning Electron Microscope) images.

Influence of micro-electrical discharge machining parameters on the surface morphology of the nickel-coated electrode