Optimisation of strictures for μ-Channel fabrications on Berilium-Copper substrate using Wire-Electric Discharge Machine for μ-heat exchanger application

Abstract

This article deals with BeCu (Beryllium-Copper alloy) substrate for μ-channel fabrication for μ-heat exchanger applications with the help of Wire-EDM (Electric Discharge Machine) operation on a hybrid μ-EDM machine. ARAS-TOPSIS multi-criteria decision methodology is used to select EDM tool material, workpiece and dielectric medium. The models established were found to be trustworthy representatives of the experimental results with prediction errors less than ±5%. SEM results have revealed an increased trend of crater diameter from 20 μm to 65 μm. The channels width was recorded in the range of 260 μm to 350 μm with the help of streo-microscope. The desirability function approach for optimizing the process parameters resulted in the nominal machining time, minimum overcut and surface roughness values of 5 minute, 40 μm and 7.6 μm respectively.