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WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels A Prerequisite for the High Heat-Transfer Rate

1
Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan
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Industrial Engineering Department, College of Engineering and Architecture, Al-Yamamah University, Riyadh 11512, Saudi Arabia
3
Raytheon Chair for Systems Engineering, Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia
*
Author to whom correspondence should be addressed.
Micromachines 2020, 11(2), 173; https://doi.org/10.3390/mi11020173
Received: 29 December 2019 / Revised: 24 January 2020 / Accepted: 5 February 2020 / Published: 7 February 2020
To get the maximum heat transfer in real applications, the surface area of the micro-features (micro-channels) needs to be large as possible. It can be achieved by producing a maximum number of micro-channels per unit area. Since each successive pair of the micro-channels contain an inter-channels fin, therefore the inter-channels fin thickness (IFT) plays a pivotal role in determining the number of micro-channels to be produced in the given area. During machining, the fabrication of deep micro-channels is a challenge. Wire-cut electrical discharge machining (EDM) could be a viable alternative to fabricate deep micro-channels with thin inter-channels fins (higher aspect ratio) resulting in larger surface area. In this research, minimum IFT and the corresponding machining conditions have been sought for producing micro-channels in copper. The other attributes associated with the micro-channels have also been deeply investigated including the inter-channels fin height (IFH), inter-channels fin radius (IFR) and the micro-channels width (MCW). The results reveal that the inter-channels fin is the most critical feature to control during the wire electrical discharge machining (WEDM) of copper. Four types of fin shapes have been experienced, including the fins: broken at the top end, deflected at the top end, curled bend at the top, and straight with no/negligible deflection.
Keywords: wire electrical discharge machining (WEDM); discharge energy; micro-channels; deflection; copper; fin-thickness; fin-radius; fin-height; surface area; heat transfer wire electrical discharge machining (WEDM); discharge energy; micro-channels; deflection; copper; fin-thickness; fin-radius; fin-height; surface area; heat transfer
MDPI and ACS Style

Ahmed, N.; Pervez Mughal, M.; Shoaib, W.; Farhan Raza, S.; M. Alahmari, A. WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels A Prerequisite for the High Heat-Transfer Rate. Micromachines 2020, 11, 173.

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