Micro-feature fabrication on SS304 stainless steel using WEDM process

Fabricating micro-pillars is a tough procedure as these features are highly debile. Wire Electro-Discharge Machining (WEDM) is a popular micromachining process to fabricate complex features on electrical conducting materials. SS304 stainless steel is commonly used in manufacturing of heating and cooling devices. A simple method of micro-pillars array fabrication on SS304 Stainless Steel material using WEDM was used through perpendicular crossed wire movement, keeping specified amount of step-over distance to form pillars. An analytical model for material removal rate prediction was developed using input parameters like spark duration, off time, voltage and current. Also, the influence of the process parameters was studied on depth and kerf width produced. Voltage and pulse-on time were found to be the major influencing parameters. Micro-featured surfaces fabricated for minimum kerf width and maximum feature depth were analysed using SEM and EDS along with the wettability study. The fabricated surfaces remained hydrophobic even after 100s.