Experimental Investigation and Parametric Optimization of Micro Holes on Inconel 718 using Developed µ-AJM Set-up

Nowadays, trends in the manufacturing industry, micromachining on difficult to machine materials such as ceramics, silicon, glass, alloys of titanium and nickel, etc. is a challenging task. Difficult to machine materials are widely used for MEMS, electronic devices, medical and aerospace industries. The higher cost is associated with the machining of these materials. Mostly µEDM, µECM and µLBM process is used to create micro features. In this paper, an attempt is made to machine a micro-hole on Inconel 718 using developed in house Micro Abrasive jet machining set-up (µ-AJM). This process has several notable advantages such as minor heat-affected zones (HAZ) and cutting forces, high machining versatility and flexibility. The experiments are planned with the proper array. The experimentally measured values of different quality characteristics have been taken as hole diameter, MRR, and machining Time. It can be noticed that Standoff Distance (SOD) is an important factor and other factors Air pressure and abrasive mesh size does not show sufficient significance. The parametric effect of different most significant input process parameters on quality characteristics has been discussed. ANOVA results showed that the Stand of Distance was the most effective parameter. The optimal condition where Abrasive size (50,100) Mix standoff distance 1 mm and inlet pressure (P1) 9 bar for minimizing the hole Diameter and lesser machining time and higher MRR on Inconel 718 material.