LAUSR

The purpose of this paper is to evaluate the feasibility of a novel gap-controlled strategy for micro-EDM process using magnetic levitation. The tool is levitated and positioned accurately using a unique actuator arm. The actuator arm attained the required positioning accuracy in the thrust (Z) direction to ensure a uniform and smooth discharge free of arcing and short circuits. Experiments were carried out using a copper tool and EDM oil on Nimonic superalloy (Grade C-263). Material removal rate (79.26 µg/min), tool wear rate (19.75 µg/min), and average surface roughness (Ra = 1.196 µm) all proved the efficacy of the developed technology. Furthermore, the machining stability and average specific energy (1.7350 J/μg) were examined and compared to the experimental results of traditional EDM, as well as literature data. Maglev μ-EDM is substantially more stable than traditional EDM, according to a comparison of the current-voltage (V-I) curve. Microholes, micropores, recast layer, and other surface topographical features are detected in a low amount using FESEM. The bidirectional material movement and elemental diffusion are shown by elemental characterization using EDX analysis.