Effects of process parameters and electrode path on surface roughness in micro-EDM milling

An analysis of surface characteristics and machining performances of micro-pockets manufactured by micro-EDM as a function of different machining conditions is presented in this paper. The pockets were obtained using four combinations of process parameters and four different tool paths. A 3D reconstruction of the pockets was performed by means of an autofocus laser probe equipment and an analysis of the surface roughness, as a function of energy level and tool path, was carried out. The effect of energy and path combinations on machining time and electrode wear were also analysed. The results showed that the surface roughness is influenced by the EDM process parameters, but not by the tool path. A comparison between the use of a single set of process parameters for the pocket manufacturing and the use of two sets of parameters (roughing and finishing) was finally executed.