Table 3.
Screening of micro-channel sizes (based on inter-channel fin thickness) and machining parameters.
| Runs | Exp. # | Wire Electrical Discharge Machining (WEDM) Parameters | Designed Inter-Channels Fin Thickness; IFT (µm) |
Actual Inter-Channels Fin Thickness; IFT (µm) |
Remarks |
|---|---|---|---|---|---|
| Trials Set 1: Inter-channel wall thickness ranging from 1000 to 250 µm (an increment of 250 µm) |
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| 1 | 1-1 | T-on = 2 µs, T-off = 25 µs, SV = 60 V, WT = 520 g, WF = 110 mm/min | 1000 | 1354 | Existence of inter-channel fin with noticeable thickness |
| 2 | 1-2 | 750 | 816 | ||
| 3 | 1-3 | 500 | 358 | ||
| 4 | 1-4 | 250 | - | Inter-channel wall gets broken | |
| Trials Set 2: Inter-channel wall thickness ranging from 500 to 300 µm (an increment of 50 µm) |
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| 5 | 2-1 | T-on = 2 µs, T-off = 25 µs, SV = 60 V, WT = 520 g, WF = 110 mm/min | 500 | 358 | Existence of inter-channel fin with noticeable thickness |
| 6 | 2-2 | 450 | 239 | ||
| 7 | 2-3 | 400 | 179 | ||
| 8 | 2-4 | 350 | - | No existence of inter-channel fin | |
| 9 | 2-5 | 300 | - | ||
| Trials Set 3: Inter-channel wall thickness ranging from 400 to 360 µm (an increment of 10 µm) |
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| 10 | 3-1 | T-on = 2 µs, T-off = 25 µs, SV = 60 V, WT = 520 g, WF = 110 mm/min | 400 | 179 | |
| 11 | 3-2 | 390 | - | No existence of inter-channel fin | |
| 12 | 3-3 | 380 | - | ||
| 13 | 3-4 | 370 | - | ||
| 14 | 3-5 | 360 | - | ||
| Trials Set 4: Inter-channel wall with constant thickness of 400 µm (confirmatory runs) |
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| 15 | 4-1 | T-on = 2 µs, T-off = 25 µs, SV = 60 V, WT = 520 g, WF = 110 mm/min | 400 | Measurements were not performed. Only CMM-based observations were captured | Inter-channel fin having a bend at the tip |
| 16 | 4-2 | 400 | |||
| 17 | 4-3 | 400 | |||
| 18 | 4-4 | 400 | |||
| 19 | 4-5 | 400 | |||
| Trials Set 5: Inter-channel wall with constant thickness of 400 µm (confirmatory runs) |
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| 20 | 5-1 | T-on = 3 µs, T-off = 30 µs, SV = 65 V, WT = 560 g, WF = 140 mm/min | 400 | - | No existence of inter-channel fin |
| 21 | 5-2 | 400 | - | ||
| 22 | 5-3 | 400 | - | ||
| 23 | 5-4 | 400 | - | ||
| 24 | 5-5 | 400 | - | ||
| Trials Set 6: Inter-channel wall with constant thickness of 400 µm (confirmatory runs) |
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| 25 | 6-1 | T-on = 1 µs, T-off = 20 µs, SV = 55 V, WT = 490 g, WF = 90 mm/min | 400 | Measurements were not performed. Only CMM-based observations were captured | Straight inter-channel fins were obtained. |
| 26 | 6-2 | 400 | |||
| 27 | 6-3 | 400 | |||
| 28 | 6-4 | 400 | |||
| 29 | 6-5 | 400 | |||