scholarly journals Applying Foil Queue Microelectrode with Tapered Structure in Micro-EDM to Eliminate the Step Effect on the 3D Microstructure’s Surface

Micromachines ◽  
2020 ◽  
Vol 11 (3) ◽  
pp. 335 ◽  
Author(s):  
Bin Xu ◽  
Kang Guo ◽  
Likuan Zhu ◽  
Xiaoyu Wu ◽  
Jianguo Lei
Keyword(s):  
Surface Quality ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Pulse Interval ◽  
Micro Edm ◽  
Shape Accuracy ◽  
Taper Angle ◽  
3D Microstructure ◽  
Step Effect ◽  
Tapered Structures

When using foil queue microelectrodes (FQ-microelectrodes) for micro electrical discharge machining (micro-EDM), the processed results of each foil microelectrode (F-microelectrode) can be stacked to construct three-dimensional (3D) microstructures. However, the surface of the 3D microstructure obtained from this process will have a step effect, which has an adverse effect on the surface quality and shape accuracy of the 3D microstructures. To focus on this problem, this paper proposes to use FQ-microelectrodes with tapered structures for micro-EDM, thereby eliminating the step effect on the 3D microstructure’s surface. By using a low-speed wire EDM machine, a copper foil with thickness of 300 μm was processed to obtain a FQ-microelectrode in which each of the F-microelectrodes has a tapered structure along its thickness direction. These tapered structures could effectively improve the construction precision of the 3D microstructure and effectively eliminate the step effect. In this paper, the effects of the taper angle and the number of microelectrodes on the step effect were investigated. The experimental results show that the step effect on the 3D microstructure’s surface became less evident with the taper angle and the number of F-microelectrodes increased. Finally, under the processing voltage of 120 V, pulse width of 1 μs and pulse interval of 10 μs, a FQ-microelectrode (including 40 F-microelectrodes) with 10° taper angle was used for micro-EDM. The obtained 3D microstructure has good surface quality and the step effect was essentially eliminated.

scholarly journals Surface Quality Improvement of 3D Microstructures Fabricated by Micro-EDM with a Composite 3D Microelectrode

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 868
Author(s):  
Jianguo Lei ◽  
Kai Jiang ◽  
Xiaoyu Wu ◽  
Hang Zhao ◽  
Bin Xu
Keyword(s):  
Surface Quality ◽  
Electrical Discharge Machining ◽  
Bonding Temperature ◽  
Three Dimensional ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Laminated Object Manufacturing ◽  
The Matrix ◽  
Filling Method ◽  
Heat Preservation

Three-dimensional (3D) microelectrodes used for processing 3D microstructures in micro-electrical discharge machining (micro-EDM) can be readily prepared by laminated object manufacturing (LOM). However, the microelectrode surface always appears with steps due to the theoretical error of LOM, significantly reducing the surface quality of 3D microstructures machined by micro-EDM with the microelectrode. To address the problem above, this paper proposes a filling method to fabricate a composite 3D microelectrode and applies it in micro-EDM for processing 3D microstructures without steps. The effect of bonding temperature and Sn film thickness on the steps is investigated in detail. Meanwhile, the distribution of Cu and Sn elements in the matrix and the steps is analyzed by the energy dispersive X-ray spectrometer. Experimental results show that when the Sn layer thickness on the interface is 8 μm, 15 h after heat preservation under 950 °C, the composite 3D microelectrodes without the steps on the surface were successfully fabricated, while Sn and Cu elements were evenly distributed in the microelectrodes. Finally, the composite 3D microelectrodes were applied in micro-EDM. Furthermore, 3D microstructures without steps on the surface were obtained. This study verifies the feasibility of machining 3D microstructures without steps by micro-EDM with a composite 3D microelectrode fabricated via the proposed method.

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.

Key Technology of Microelectrode Array Fabrication by Ultrasonic Enhanced Micro-EDM

2007 ◽  
Author(s):  
Guanxin Chi ◽  
Weiliang Zeng ◽  
Desheng Dong ◽  
Zhenlong Wang
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Microelectrode Array ◽  
Electrical Discharge Machining ◽  
Short Circuit ◽  
High Price ◽  
Hole Array ◽  
Micro Edm ◽  
Plane Plate ◽  
Micro Hole

Micro electrical discharge machining (EDM), enhanced with ultrasonic vibration, is explored and assessed as a new technology for developing microelectrode array, for microelectrode array fabricated by LIGA has shortcomings such as complex technology and high price. Based on the mechanism of micro-EDM, micro-hole array discharges to fabricate microelectrode array by reverse copying. In the process of reverse copying, the thicker rod electrode can’t rotate, resulting in electric arc and short-circuit easily, so it is necessary to add ultrasonic vibration on the plane plate electrode. According to the technology, a set of micro-EDM system is designed and developed. On the machining system, influence of ultrasonic vibration is analysed from the way of vibration mechanics through theoretical analysis and experimental observation. Compared with machining without ultrasonic vibration, single discharging energy decreases 1/2, discharge frequency improves three times, machining efficiency increases two times and better surface quality is achieved. Finally, 5×5 arrays of microelectrode and microhole made by these microelectrode arrays are got, the diameter of single electrode is less than 30μm and height-to-width aspect ratio is more than 8, moreover these arrays of microelectrode and micro-hole have very good surface quality.

Study on the Effect of Nano and Micro MoS2 Powder in Micro-Electrical Discharge Machining

2011 ◽  
Vol 264-265 ◽  
pp. 1450-1455 ◽  
Author(s):  
Gunawan Setia Prihandana ◽  
Tutik Sriani ◽  
Kei Prihandana ◽  
Yuta Prihandana ◽  
Muslim Mahardika ◽  
...  
Keyword(s):  
Surface Quality ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Micro Edm ◽  
Micro Electrical Discharge Machining ◽  
Powder Suspension ◽  
Size Powder

The application of powder mixed dielectric to improve the efficiency of electrical discharge machining (EDM) has been acknowledged extensively. However, the study of micro-size powder suspension in micro-EDM field is still limited. In this research, nano and micro size powder of MoS2 were used as catalyst agent. Powder suspension in different size was able to provide significant improvement in material removal rate and surface quality to increase the efficiency in μ- EDM processes.

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.

Experimental Studies on Dry WEDM in Improving Surface Quality

2009 ◽  
Vol 626-627 ◽  
pp. 327-332 ◽  
Author(s):  
Tong Wang ◽  
Yu Mei Lu ◽  
Q. Chen ◽  
S.H. Zhou
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Experimental Studies ◽  
Pulse Interval ◽  
Wire Length ◽  
Dry Wedm ◽  
Dry And Wet Conditions

This study investigates the dry wire electrical discharge machining (WEDM) in multiple cut. To improve surface quality with high-speed WEDM (HS-WEDM), a new procedure as Gas-liquid Combined Multiple Cut (roughing is processed in dielectric liquid, and semi-finishing is in liquid or gas, while the finishing is in gas) is presented. Effects of pulse duration, pulse interval, peak current, offset, wire winding speed and wire length on roughness, straightness and removal rate had been studied in dry and wet conditions. Experiment results show that multiple cut with dry WEDM in semi-finishing and finishing can improve surface roughness significantly.

Technique of Brass Spiral Structure Deposition Using Micro EDM in Gas

2007 ◽  
Vol 329 ◽  
pp. 595-600
Author(s):  
Zhen Long Wang ◽  
Bai Dong Jin ◽  
Guo Hui Cao ◽  
Z.W. Wei ◽  
Wan Sheng Zhao
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Spiral Structure ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Processing Parameters ◽  
Pulse Interval ◽  
Tool Electrode ◽  
External Diameter

This paper proposes a new deposition method using micro electrical discharge machining (EDM) to deposit micro spiral structure in gas. First, the basic principles of micro electrical discharge deposition (EDD) are analyzed and the realized conditions are predicted. Then with an ordinary EDM shaping machine, brass as the electrode, high-speed steel as the workpiece, a lot of experiments are carried out on the micro spiral structure deposition in air. The effects of major processing parameters, such as the discharge current, discharge duration, pulse interval, gravity and working medium, are obtained. As a result, a 19-circle micro spiral structure with 0.19mm in external diameter, 0.1mm in wire diameter and 3.39mm in height is deposited. Measurements show that the deposited material has obvious delaminating structure, the components of which depend on those of the tool electrode material, although Zn in the electrode is oxidized to ZnO. This method establishes the research basis for micro three-dimensional deposition machining.

Swing Mechanism for Micro EDM Drilling of Fuel Jet Nozzles

2012 ◽  
Vol 591-593 ◽  
pp. 391-395 ◽  
Author(s):  
Hao Tong ◽  
Yong Li ◽  
Long Zhang
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Micro Edm ◽  
Taper Angle ◽  
Micro Electrical Discharge Machining ◽  
Electrode Wire ◽  
Fuel Jet ◽  
Micro Holes ◽  
Edm Drilling ◽  
Fixed Center

To improve the spray effects of fuel-jet nozzles, the deep micro-holes of the nozzles require taper angle 0°-2° along jet direction. In this paper, a taper-swinging mechanism (TSM) is designed to swing a taper angle on an electrode wire for micro electrical discharge machining (EDM) of micro-taper holes. The features of TSM are as follows. First, the electrode wire and its guider are swung simultaneously during the micro-EDM drilling. Second, the center of a fixed sphere as the taper vertex is positioned on the surface of workpiece. Thirdly, non-rotating of the electrode wire and the fixed center avoid the errors of the swing motion. The taper holes with the corresponding angles of 0.12°, 0.40°, 0.83°, and 1.32° were machined by using TSM. The batch production showed that the consistency accuracy of holes’ diameters reached 4μm. In addition, the TSM was applied in a micro EDM machine tool.

Design and calibration of an IVEM for general 3-dimensional imaging of non-diffracting materials

1992 ◽  
Vol 50 (2) ◽  
pp. 1040-1041
Author(s):  
Neil Rowlands ◽  
Jeff Price ◽  
Michael Kersker ◽  
Seichi Suzuki ◽  
Steve Young ◽  
...  
Keyword(s):  
3D Imaging ◽  
Tomographic Reconstruction ◽  
Three Dimensional ◽  
3 Dimensional ◽  
3D Microstructure ◽  
Image Translation ◽  
Digital Correlation ◽  
On Line ◽  
Mechanical Stage ◽  
Projection Angle

Three-dimensional (3D) microstructure visualization on the electron microscope requires that the sample be tilted to different positions to collect a series of projections. This tilting should be performed rapidly for on-line stereo viewing and precisely for off-line tomographic reconstruction. Usually a projection series is collected using mechanical stage tilt alone. The stereo pairs must be viewed off-line and the 60 to 120 tomographic projections must be aligned with fiduciary markers or digital correlation methods. The delay in viewing stereo pairs and the alignment problems in tomographic reconstruction could be eliminated or improved by tilting the beam if such tilt could be accomplished without image translation.A microscope capable of beam tilt with simultaneous image shift to eliminate tilt-induced translation has been investigated for 3D imaging of thick (1 μm) biologic specimens. By tilting the beam above and through the specimen and bringing it back below the specimen, a brightfield image with a projection angle corresponding to the beam tilt angle can be recorded (Fig. 1a).

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