Optimization of electrochemical etching process for manufacturing of micro electrodes for micro-EDM application

2020 ◽  
pp. 095440542095896
Author(s):  
Sucharita Saha ◽  
Amit Kumar Ball ◽  
Arpita Mukherjee ◽  
Arjita Das ◽  
Saurav Halder ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Electrochemical Etching ◽  
Etching Process ◽  
Tool Electrode ◽  
Micro Edm ◽  
Nano Scale ◽  
Geometrical Features ◽  
Edm Electrodes ◽  
Micro Parts ◽  
Metal Products

Application of Micro-Nano scale Electrical Discharge Machining is rapidly growing in manufacturing of metal products irrespective of its hardness having geometric features in range of micrometer to nanometer scale. To achieve such small geometrical features, smaller dimensional tool electrode is required. However fabrication of this tiny electrode with desired dimension and also handling of such tiny electrodes is a primary aspect that needs to be investigated systematically to use the Micro-Nano scale EDM in batch production of micro parts. In this work authors investigate the application of electrochemical etching process for fabricating EDM electrodes smaller than 10 µm. While the smallest electrode fabricated with the optimized parameter is 3.33 µm, their performance as electrode in micro-EDM has been studied systematically. To the best of authors’ knowledge such studies are not reported in the published literatures. However, the fabrication of such smaller size features by applying alternating current in ECE has been attempted previously but not for micro-EDM applications.

scholarly journals An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

2017 ◽  
Vol 64 (2) ◽  
pp. 149-163 ◽  
Author(s):  
Govindan Puthumana
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Micro Edm ◽  
Modeling And Analysis ◽  
Micro Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Main Effect

AbstractTo achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a regression relationship between tool wear ratio and the process inputs has been developed.

Performance Analysis of Rapid Tool in Electrical Discharge Machining During Machining of Titanium Alloy (Ti6Al4V)

2018 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Performance Measures ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Machining Performance ◽  
Edm Electrodes ◽  
Titanium Alloy Ti6al4v ◽  
The Cost ◽  
Grey Relational ◽  
Conventional Machining

Titanium and its alloys are a class of metallic materials having high strength to weight ratio with excellent properties of resistance to temperature, corrosion and oxidation. These properties increase their use in aerospace, chemical and biomedical industries. Electrical discharge machining (EDM), a non-conventional machining process, is the most suitable process for the machining of titanium and its alloys. Generally, tool electrode for EDM application is prepared through various conventional and non-conventional machining processes. The cost of production of EDM electrodes accounts for more than 50% of the cost of the final product. Therefore, additive manufacturing (AM) technology can be suitably applied for direct manufacturing of the complex EDM electrodes. Selective laser sintering (SLS) is one of the appropriate AM processes for preparation of EDM tool electrode. In the present work, machining performance of the AlSi10Mg tool electrode produced through AM process along with copper and brass tool electrodes have been studied considering titanium alloy (Ti6Al4V) as work piece material and commercial grade EDM 30 oil as dielectric fluid. In addition to the tool electrodes, two more EDM parameters such as pulse-on-time (Ton) and discharge current (Ip) have been considered. Four performance measures like material removal rate (MRR), tool wear rate (TWR), average surface roughness (Ra) and surface crack density (SCD) are used to assess the machining performance. In order to reduce the number of experiments, design of experiment (DOE) approach like Taguchi’s L9 orthogonal array is used. Since the performance measures are conflicting in nature, grey relational analysis (GRA) is used to convert four performance measures into an equivalent single performance measure. The best parametric condition is reported for optimal grey relational grade.

Microstructure and Electrode Discharge Machining of TiN/Si3N4 Composites

2005 ◽  
Vol 475-479 ◽  
pp. 1337-1340
Author(s):  
Chien Cheng Liu ◽  
Jow Lay Huang
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Ceramic Composites ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Si3n4 Ceramic ◽  
Whole Process ◽  
Electrode Discharge ◽  
Scanning Electron

Conductive TiN/Si3N4 ceramic composites were processed by electrical discharge machining (EDM) and their microstructure and conductivity investigated. A low electrical resistivity of 1.25×10-3Ω.cm was obtained in 40vol%TiN/Si3N4 composite. The whole process of tool electrode wear is evaluated by sinker-EDM. The machined surfaces of TiN/Si3N4 ceramic composites were examined by scanning electron microscopy (SEM) and profilometry to determine the surface finish. Micropores of 700µm in depth and 70µm in diameter were successfully machined in TiN/ Si3N4 composites by the micro-EDM method.

Fabrication of Functional Gradient Materials Electrode and its Application in Micro-EDM

2017 ◽  
Vol 868 ◽  
pp. 151-157
Author(s):  
Xiao Peng Li ◽  
Yuan Gang Wang ◽  
Fu Ling Zhao ◽  
Meng Hua Wu
Keyword(s):  
Electrical Discharge Machining ◽  
Gradient Material ◽  
Homogeneous Material ◽  
Tool Electrode ◽  
Micro Edm ◽  
Gradient Materials ◽  
Functional Gradient ◽  
Micro Electrical Discharge Machining ◽  
Functional Gradient Material ◽  
Edm Process

The concept and the primary preparation method of functional gradient materials are described in this paper. Functional gradient material is prepared as a tool electrode by electrochemical method and its performance is further tested in the micro electrical discharge machining (micro-EDM) experiments. Compared with the homogeneous material electrode, the functional gradient material electrode can effectively inhibit the wearing of the tool electrode and improve the distribution trend of current density during the micro-EDM process. The results disclose the prospects for functional gradient material to be used as tool electrode in the micro-EDM process.

Micro-Forming Process and Microstructure of Deposit by Using Micro EDM Deposition in Air

2008 ◽  
Vol 375-376 ◽  
pp. 153-157 ◽  
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Bai Dong Jin
Keyword(s):  
High Speed ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
High Speed Steel ◽  
Solidification Process ◽  
Pulse Interval ◽  
Tool Electrode ◽  
Micro Edm ◽  
Forming Process ◽  
Long Pulse

Based on analysis of the mechanism of Electrical Discharge Machining (EDM) and the characteristics of deposition processing, the processing conditions of micro EDM Deposition (micro EDD) are determined. Micro EDD is a new EDM method taking air as machining medium, using narrow pulse width, long pulse interval, low discharge current and connecting the tool electrode with the anode of pulse generator. Using EDM shaping machine and brass, tungsten and steel as tool electrode respectively, micro cylinders are deposited on high-speed steel surface. And then the microstructure of deposit is analyzed detailedly. Results show that elements of the deposited material distribute uniformly, whose components depend on the tool electrode material. As the high cooling rate of the solidification process, the deposit grain size refines obviously, which leads to the hardness of tungsten or steel deposit increasing. Moreover, the Metallurgical bonding has occurred on the interface between deposit and high-speed steel base, whose thickness is about 5μm.

scholarly journals Micro Electrochemical Machining of Array Micro-Grooves Using In-Situ Disk Electrode Fabricated by Micro-WEDM

Micromachines ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 66 ◽  
Author(s):  
Yukui Wang ◽  
Han Wang ◽  
Yuxin Zhang ◽  
Xiaolong He ◽  
Zhenlong Wang ◽  
...  
Keyword(s):  
High Precision ◽  
Large Scale ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Tool Electrode ◽  
Disk Electrode ◽  
Micro Ecm ◽  
Micro Parts ◽  
Micro Wedm

This paper develops an array micro-grooves manufacturing method using micro electrochemical machining (ECM) with disk electrode, which is prepared by in-situ micro wire electrical discharge machining (WEDM). This technology focuses on the difficulty of array structure manufacture in micro-electro-mechanical systems (MEMS). A micro-ECM system is built based on the micro-WEDM machine to achieve high precision processing of the array micro-grooves. Since micro-WEDM has good performance in high precision machining of the rotating structure, single and multi-edge disk electrodes can be fabricated in-situ using graphite. The as-prepared disk tool electrode is directly used for micro-electrochemical milling of the array micro-grooves without disassembling away from the device, which avoids the positioning error caused by the re-clamping of the disk electrode. With the advantages of high surface quality and no electrode loss, micro-ECM improves the manufacture performance of the micro-parts. Through wire path optimization, the shape accuracy of the disk edge is improved. After the research of the micro-ECM parameters, the process is improved, and finally, the high precision array micro-grooves are obtained. This method combines the advantages of micro-WEDM and disk electrode micro-ECM milling, and it is convenient for large-scale manufacture of array micro-structures on micro-parts and MEMS.

Material Removal and Fracture Detection in Micro-EDM Processes

2011 ◽  
Vol 462-463 ◽  
pp. 1092-1096 ◽  
Author(s):  
Muslim Mahardika ◽  
Gunawan Setia Prihandana ◽  
Takashi Endo ◽  
Suyitno ◽  
B. Arifvianto ◽  
...  
Keyword(s):  
Pulse Energy ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Micro Machining ◽  
Fracture Detection ◽  
Charge Voltage ◽  
Discharge Pulse ◽  
Micro Electrical Discharge Machining

The important thing in micro-machining is its accuracy. The Micro-Electrical Discharge Machining (micro-EDM) is a promising method in micro-machining, because (1) the process is independent on the hardness of the workpiece but only depends on its thermal conductivity and melting point and (2) it can be used to machine materials with highly complex geometrical shapes using a simple-shaped tool electrode. However, the process in micro-EDM is not totally well-known, especially related to the formation of discharge pulse energy and the fracture phenomena. In the micro-EDM processes, the formation of discharge pulse energy is a complex phenomenon, since it is related to many parameters such as discharge gap, charge voltage, capacitance, and tool electrode wear. In this paper, the Acoustic Emission (AE) sensor is used to detect the changes of discharge pulse energy during machining of brass using micro-EDM. The results shows that the AE signals can detect and explain the fracture phenomena during the micro-EDM processes.

Experimental Research of Micro Reversible Electrical Discharge Machining

2009 ◽  
Vol 69-70 ◽  
pp. 177-181
Author(s):  
Zi Long Peng ◽  
Zhen Long Wang ◽  
Ying Huai Dong ◽  
Hui Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Metallurgical Bonding ◽  
Machining System ◽  
Micro Structures ◽  
Edm Process

Based on the principle of micro electrical discharge machining (EDM), a reversible machining method is proposed, which can achieve depositing or removing selectively metal material for the fabrication of micro structures. It is easy to transform the machining process from deposition to removal in one machining system. The characteristics of the deposited material show that the components of deposited material are almost the same as those of the tool electrode, and the metallurgical bonding has formed on the interface between the deposited material and the base. Moreover, the deposited material has well machinability in different micro EDM selective removal process, including micro EDM die-sinking and micro EDM milling. As a result, a micro square column with 0.1mm in side length, 0.88mm in height and a micro cylinder with 0.14mm in diameter, 1.18mm in height were fabricated by using the micro reversible EDM process.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Recent Patents on Micro-EDM Milling

2020 ◽  
Vol 13 (3) ◽  
pp. 219-229
Author(s):  
Baocheng Xie ◽  
Jianguo Liu ◽  
Yongqiu Chen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Processing Method ◽  
Electrode Wear ◽  
Micro Edm ◽  
Processing Efficiency ◽  
Processing Methods ◽  
Machining Quality ◽  
Micro Electrical Discharge Machining

Background: Micro-Electrical Discharge Machining (EDM) milling is widely used in the processing of complex cavities and micro-three-dimensional structures, which is a more effective processing method for micro-precision parts. Thus, more attention has been paid on the micro-EDM milling. Objective : To meet the increasing requirement of machining quality and machining efficiency of micro- EDM milling, the processing devices and processing methods of micro-EDM milling are being improved continuously. Methods: This paper reviews various current representative patents related to the processing devices and processing methods of micro-EDM milling. Results: Through summarizing a large number of patents about processing devices and processing methods of micro-EDM milling, the main problems of current development, such as the strategy of electrode wear compensation and the development trends of processing devices and processing methods of micro-EDM milling are discussed. Conclusion: The optimization of processing devices and processing methods of micro-EDM milling are conducive to solving the problems of processing efficiency and quality. More relevant patents will be invented in the future.

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