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Inconel 600 is widely used in various engineering applications including aerospace, chemical and food processing industries. Traditional machining of Inconel 600 is difficult due to high tool wear, cutting forces, temperature, surface roughness and dimensional inaccuracy. The present article describes research work involved in micro-EDM of Inconel 600 to investigate material removal rate, tool wear rate and dimensional overcut. Major process parameters, namely, voltage, duty ratio and sensitivity are considered. Response surface methodology is used to design the experiments. A novel tooling approach, i.e. copper foil tool is proposed in the present study for machining of micro-slits on the workpiece. It is observed that material removal increases with an increase in voltage, optimum duty ratio and sensitivity. Tool wear decreases with a decrease in voltage, moderate duty ratio and sensitivity. A mathematical model is developed for predicting the material removal rate on the basis of experimental results. Multi-objective optimisation is performed by using Grey relational analysis. A confirmation experiment validates the improvement in responses under optimised values of process parameters. It is observed that the use of foil tool improves material removal and dimensional accuracy of the workpiece. A novel foil tooling approach is helpful in the machining of complex microfeatures with high material removal rate and dimensional accuracy.

A novel tooling approach for micro electrical discharge machining of micro-slits on Inconel 600 using foil tools