Micro-Abrasive Water Jet and Micro-WEDM Process Chain Assessment for Fabricating Microcomponents

The capability to manufacture high-precision components with microscale features is enhanced by the combination of different micromanufacturing processes in a single process chain. This study explores an effective process chain that combines micro-abrasive water jet (mu-AWJ) and microwire electrical discharge machining (mu-WEDM) technologies. An experimental spring component is chosen as a leading test case, since fine geometric features machining and low roughness on the cut walls are required. The advantages deriving from the two technologies combination are discussed in terms of machining time, surface roughness, and feature accuracy. First, the performances of both processes are assessed by experimentation and discussed. Successively, different process chains are conceived for fabricating two test cases with different sizes, displaying some useful indications that can be drawn from this experience.