Developing Meso and Microholes by Spark-Erosion Based Drilling Processes: A Critical Review

Area of Science:

• Manufacturing Engineering
• Materials Science
• Precision Engineering

Background:

• Growing demand for miniature components necessitates advanced manufacturing techniques.
• Micro-drilling is crucial for smart manufacturing, creating holes less than 1mm (microholes) and 1-10mm (mesoholes).
• These fine holes are essential for micro-parts across various industries.

Purpose of the Study:

• To present a comprehensive review of research on fine hole drilling using spark erosion-based processes.
• To highlight key aspects including materials, hole specifications, and process parameters.
• To facilitate researchers by showcasing spark erosion's capabilities in miniature hole fabrication.

Main Methods:

• Extensive literature review of spark erosion-based processes for drilling micro and mesoholes.
• Analysis of work and tool electrode materials used in spark erosion drilling.
• Compilation of data on drilled hole specifications, types (through/blind), process parameters, and performance metrics.

Main Results:

• Spark erosion machining is a viable and effective method for drilling fine holes in diverse engineering materials.
• Detailed findings on various process parameters and their impact on hole quality and performance are presented.
• The review consolidates knowledge on electrode materials and achievable hole specifications.

Conclusions:

• Spark erosion machining offers significant capabilities for the precise fabrication of miniature holes.
• The review provides a valuable resource for researchers and engineers in the field of micro-manufacturing.
• Future research directions are identified to further advance spark erosion techniques for fine hole drilling.