Micro-mold insert fabrication in aluminum 7075 using micro-EDM

Anthuvan, Naveen (avtor), Vijayan, Krishnaraj (avtor), Valentinčič, Joško (avtor), Mohana Krishnan, M. (avtor)

This work presents the fabrication and optimization of a T-shaped micro-mold insert using Micro-Electrical Discharge Machining. Aluminum 7075 was employed as the work material, while EC – grade copper electrode was used as the tool. Experiments were designed using a Taguchi L9 orthogonal array to vary current, voltage, and duty cycle. ANOVA revealed that current is the most dominant influencing parameter, contributing to more than 80 % of the variation in the output responses, followed by duty cycle, whereas voltage exhibited the least influence. The maximum material removal rate of 36.3696 mm▫$^{3}$▫ /min, minimum electrode wear rate of 0.2837 mm▫$^{3}$▫ /min, and a maximum dimensional accuracy of 92.65 % were achieved. GRA applied to the L9 experimental data identified the optimal parameter combination as 3A current, 50 V voltage, and 8s duty cycle. To improve data reliability, the L9 dataset was augmented to an L27 dataset using the Mix-up data augmentation method. Subsequent GRA and ANN optimization of the L27 dataset consistently confirmed current as the primary influencing factor, followed by duty cycle and voltage. The optimized parameters from the L27 analysis were 3 A current, 40 V voltage, and 8 s duty cycle, which are adopted as the final machining conditions.

• Jezik: Angleški jezik
• Ključne besede: EDM, microinsert, GRA, ANN, electrical discharge machining, grey relational analysis, neural network
• Vrsta gradiva: Članek v reviji
• Tipologija: 1.01 - Izvirni znanstveni članek
• Organizacija: FS - Fakulteta za strojništvo
• Status publikacije: Objavljeno
• Različica publikacije: Recenzirani rokopis
• Leto izida: 2026
• Št. strani: Str. 1350-1361
• Številčenje: Vol. 41, iss. 9
• PID: 20.500.12556/RUL-184428
• UDK: 621.9.048:669.71
• ISSN pri članku: 1042-6914
• DOI: 10.1080/10426914.2026.2682781
• COBISS.SI-ID: 282251779
• Datum objave v RUL: 07.07.2026

Gradivo je del revije

• Naslov: Materials and manufacturing processes
• Skrajšan naslov: Mater. manuf. process.
• Založnik: Taylor & Francis
• ISSN: 1042-6914
• COBISS.SI-ID: 1485851

Sekundarni jezik

• Jezik: Slovenski jezik
• Ključne besede: elektroerozija, elektroerozivna obdelava, orodni mikro vložek, siva relacijska analiza, nevronske mreže

Projekti

• Financer: Drugi - Drug financer ali več financerjev
• Program financ.: Department of Science and Technology, India
• Številka projekta: Grant S. No 22
• Naslov: India-Slovenia bilateral project

• Financer: ARIS - Javna agencija za znanstvenoraziskovalno in inovacijsko dejavnost Republike Slovenije
• Številka projekta: BI-IN/22-24-016-2022
• Naslov: Izdelovalne verige za serijsko izdelavo mikroreaktorskih sistemov