Micro-pillar structuring while processing of titanium via tool redressal method

In the present experimentation, a micropillar is generated on a titanium sheet with tungsten carbide of 500 µm diameter by micro-EDM milling process. Discharge energy, tool rotation, and tool feed are selected as machining parameters. Taguchi’s L16 technique decides experimental sequences. Moreover, the first objective is to investigate the effect of process parameters on MRR, TWR, micro pillar width, and heigh to find the efficient set of parameters for micro pillar generation. The second objective is to fabricate the µ-pillar based on the outcome of the first objective. FESEM and XRD investigation reveals that higher discharge Energy and tool rotation damage the surface with heavy flush-out mass, creating cracks, voids, craters, and waviness on the machined surface. Accordingly, 8.45 µj and 800 rpm provided an efficient microchannel for the generation of micropillars. Furthermore, effect of tool wear compensation is also included in the process to justify the uniformity of geometrical dimensions.