Study on burr formation in micro-machining using micro-tools fabricated by micro-EDM

A microstructure assembled into another part using the mechanical elastic self-deformation assembly technology is proposed in the paper. To attain the self-deformation during assembling, the assembly joint on the microstructure is analytically designed as the feature with an appropriate taper and cross clearance. Take account of the accuracy, the whole process from micro-fabrication to micro-assembly is carefully planned and practiced under a micro-EDM machining center system which consists of vertical micro-EDM with dividing mechanism, and horizontal micro-machining mechanism, which is referred to as on-process micro-assembly. To illustrate the micro-assembly strategies and procedures, a micro-rotor production including assemble a tungsten carbide four-phase micro-rotor into an alumina base has been provided and discussed.

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Modeling Analysis of Micro-Burr Formation

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.381.86 ◽

2011 ◽

Vol 381 ◽

pp. 86-89 ◽

Cited By ~ 1

Author(s):

Yong Hua Xiong ◽

Gui Cheng Wang ◽

Jian Chen ◽

Hai Lin Li

Keyword(s):

Numerical Simulations ◽

Formation Mechanism ◽

Cutting Parameters ◽

Machining Process ◽

Burr Formation ◽

Tool Geometry ◽

Micro Machining ◽

Two Dimensional ◽

Modeling Analysis ◽

General Rules

One of the main problems in the process of micro-machining for small and precision parts is that micro-burr will be generated. This paper carried out the two-dimensional numerical simulations with ABAQUS, which simulated the effects on burr formation coming from the micro-burr formation mechanism, tool geometry and cutting parameters in micro-machining process. The general rules of various factors impacting on burr formation were obtained in micro-machining process.

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Burr Formation in Micro-machining Aluminum, 6061-T6

Initiatives of Precision Engineering at the Beginning of a Millennium ◽

10.1007/0-306-47000-4_8 ◽

2005 ◽

pp. 47-51 ◽

Cited By ~ 5

Author(s):

Kiha Lee ◽

Boris Stirn ◽

David A. Dornfeld

Keyword(s):

Burr Formation ◽

Micro Machining

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Research on Multifunctional Micro Machining Equipment

Materials Science Forum ◽

10.4028/www.scientific.net/msf.471-472.37 ◽

2004 ◽

Vol 471-472 ◽

pp. 37-42 ◽

Cited By ~ 8

Author(s):

B.X. Jia ◽

Zhen Long Wang ◽

Fu Qiang Hu ◽

Xiao Hai Li ◽

Wan Sheng Zhao

Keyword(s):

New Technologies ◽

Electrochemical Machining ◽

Micro Edm ◽

Micro Machining ◽

Electro Discharge Machining ◽

Micro Ecm ◽

Micro Holes ◽

Micro Hole ◽

Series Of Experiments ◽

Frequency Pulse

To perform several micro-machining on same machine tool, a micro machining equipment was researched and developed. The equipment adopts some high and new technologies. It is equipped with high precision XYZ stage, a spindle with high rotation accuracy and variable rotation speed, a granite worktable, a block electro discharge grinding unit for machining micro rod, a ultrasonic vibration unit for workpiece vibrating, a high frequency pulse power supply for micro-ECM and a video microscopic system with high enlargement factor. The equipment can perform micro electro discharge machining (EDM), micro electrochemical machining (ECM), micro ultrasonic machining (USM) as well as their combination. It can also machine 3D microstructures. A series of experiments were carried out. Using micro-EDM, micro rods with the diameter of less than 5µm were ground on block electrode, micro holes and 3D microstructures were obtained. Shaped holes were machined by using combination of micro-EDM and micro-USM. A micro hole with the diameter of 100µm was machined via micro-ECM.

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Laser Induced Plasma Micro-Machining

ASME 2010 International Manufacturing Science and Engineering Conference, Volume 2 ◽

10.1115/msec2010-34242 ◽

2010 ◽

Cited By ~ 5

Author(s):

Kumar Pallav ◽

Kornel F. Ehmann

Keyword(s):

Tool Wear ◽

Material Removal ◽

Machining Process ◽

Micro Edm ◽

Micro Machining ◽

Workpiece Surface ◽

Laser Induced Plasma ◽

New Process ◽

Explosive Expansion ◽

Edm Process

A new micro-machining process that is motivated by the need to overcome the various limitations associated with the micro-EDM (μ-EDM) process is introduced. The limitations in μ-EDM are primarily due to the requirement of a conductive electrode and workpiece, tool wear, and complex wear compensation strategies. The new process, termed “laser-induced plasma micro-machining” uses a laser beam to generate plasma in a dielectric near the workpiece surface whose explosive expansion results in material removal by mechanisms similar to those that occur in μ-EDM.

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A review on micro-milling: recent advances and future trends

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-06445-w ◽

2020 ◽

Author(s):

Barnabás Zoltán Balázs ◽

Norbert Geier ◽

Márton Takács ◽

J. Paulo Davim

Keyword(s):

Cutting Temperature ◽

Micro Milling ◽

Burr Formation ◽

High Tech ◽

Formation Mechanisms ◽

Future Trends ◽

Research Directions ◽

Industrial Sectors ◽

Micro Tools ◽

Chip Removal

AbstractRecently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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High aspect ratio of micro hole drilling by Micro-EDM with different cross-section shape micro tools for flushing process

Procedia CIRP ◽

10.1016/j.procir.2020.01.161 ◽

2020 ◽

Vol 95 ◽

pp. 550-553

Author(s):

Tzu-Wei Huang ◽

Dong-Yea Sheu

Keyword(s):

Aspect Ratio ◽

Cross Section ◽

High Aspect Ratio ◽

Hole Drilling ◽

Micro Edm ◽

Cross Section Shape ◽

Section Shape ◽

Micro Hole ◽

Micro Tools

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The Deposition and Removal Process for Micro Machining Based on Electrical Discharge

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.472-475.2448 ◽

2012 ◽

Vol 472-475 ◽

pp. 2448-2451

Author(s):

Zi Long Peng ◽

Yi Nan Li

Keyword(s):

Electrical Discharge ◽

Deposition Process ◽

Process Conditions ◽

Tool Electrode ◽

Electrode Wear ◽

Discharge Process ◽

Micro Edm ◽

Micro Machining ◽

Removal Process ◽

Micro Structures

Based on the analysis of electrical discharge process characteristics, the principle of achieving deposition process and removal process using micro EDM is proposed. By controlling the tool electrode wear in one micro EDM system, it is easy to achieve the different machining type of deposition or removal process. Centering on the problem of tool electrode wear, the process conditions of the deposition and removal including machining polarity, machining dielectric medium, discharge parameters and the tool electrode rotation are researched detailedly. Results show that under the discharge phenomena between electrodes, metal material can be deposited to form micro structures, and the transfer strategy from deposition to removal process can be controlled easily. The machining procedure for fabrication of micro structures based on depostion and removal process are put forward. And finally, some examles with well shape and dimension accuracy are given to validate the processing ability for micro machining.

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