Electrochemical Spark Micromilling (ECSMM) is frequently utilized for microchannel fabrication on nonconducting materials due to its ability to produce simple to complex geometries with high dimensional accuracy and minimal heat damage. Significant advancements have been made in ECSMM for polymer fiber and particle-reinforced nanocomposites, focusing on microchannel shape. However, several challenges persist in achieving precise control over fabrication quality. This study evaluates the effects of voltage (V), tool rpm (N), Ton time, and electrolyte concentration (EC) on silica-reinforced epoxy nanocomposite (SRENC) using fluted tungsten carbide tool electrodes. Response surface methodology (RSM) was employed to generate damage-free straight microchannels, analysing material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra). Results indicate that higher voltage and electrolyte concentration enhance MRR, while excessive Ton time negatively impacts Ra. The desirability function approach (DFA) yielded optimal MRR, Ra, and TWR as 0.431 mg/min, 3.021 μm, and 0.028 mg/min, respectively, with deviations within ±5%. Multi-objective optimization (MOO-GA) at 120 V, 12 rpm, 100 g/l, and 2000 µs Ton time predicted MRR, Ra, and TWR with slight ±10% variations compared to experimental results. Microstructural analysis confirmed uniform material removal and reduced heat damage. The study highlights the influence of machining parameters on fabrication quality and suggests that precise parameter optimization can significantly enhance microchannel integrity on SRENC.
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