Research of Layered Machining Experiment by Micro-EDM

2014 ◽  
Vol 678 ◽  
pp. 601-605
Author(s):  
Jin Kai Xu ◽  
Lin Shuai Zhang ◽  
Fei Huang
Keyword(s):  
Machine Vision ◽  
Processing Time ◽  
Groove Depth ◽  
Optical Microscope ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Machining Quality ◽  
Processing Error ◽  
Orthogonal Machining

The effect of electrode wear is significant on machining quality, in order to ensure the processing precision of micro-EDM milling, need to give reasonable compensation for the tool electrode. In this paper, based on the model of fixed length compensation method to machining the micro groove with micro-EDM by layered milling experiment, moreover, adopted the orthogonal machining path and the machine vision technology to obtain the stable end of the electrode image after processing, and then determine the reasonable path of trajectory overlap. The experimental results show that, the electrode compensation model can availably compensate the electrode wear, and the processing time is shortened by 50% with the machining method of orthogonal trajectories, and the method can make the residual cut remove obviously, gained good machining precision. We observe the bottom section linearity of micro groove is very good and the processing error of the micro groove depth is about 2 μm by the optical microscope.

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.

CAD/CAM Integration System of 3D Micro EDM

2007 ◽  
Author(s):  
Hao Tong ◽  
Jing Cui ◽  
Yong Li ◽  
Yang Wang
Keyword(s):  
Real Time ◽  
Numerical Control ◽  
Machining Process ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Model Design ◽  
Integration System ◽  
Cad Cam ◽  
Micro Structures

In 3D scanning micro electro discharge machining (EDM), the CAD/CAM systems being used in mechanical milling of numerical control (NC) are unable to be applied directly due to the particularity of tool electrode wear. Based on industry computer and RT-Linux software platform, a CAD/CAM integration system of 3D micro EDM is developed. In the developed CAD/CAM integration system, the hardware includes mainly a micro feed mechanism for servo control, XY worktable, a high frequency pulse power supply, monitoring circuits etc., and the functions consist of model design, scanning path planning and simulation, NC code generation and post processing, real-time compensating of tool electrode wear, and machining control of states and process. The method of double buffer storage is adopted to transmit numbers of NC machining data. Servo scanning EDM method is used to realize real-time electrode wear compensating and thereby 3D micro structures are machined automatically. The machining experiments are made about model design, parameters optimizing, and process control. The typical 3D micro structures with space curved surfaces and lines have been machined such as micro prism, micro half tube, camber correlation line, and so on. The machining process and results show that the CAD/CAM integration system has the characters of higher real-time, reliability, and general using.

Study of Electrode Wear Ratio of Piezoelectric Self-Adaptive Micro-EDM

2013 ◽  
Vol 589-590 ◽  
pp. 505-510
Author(s):  
De Zheng Kong ◽  
Qin He Zhang ◽  
Xiu Zhuo Fu ◽  
Ya Zhang
Keyword(s):  
Open Circuit Voltage ◽  
Removal Rate ◽  
Open Circuit ◽  
The Self ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Traditional Concept ◽  
Wear Ratio ◽  
Self Adaptive

Micro Electrical discharge machining (Micro-EDM) is a non-traditional concept of machining. It is very suitable for machining micro parts of Micro-electromechanical Systems (MEMS). However, the application of micro-EDM is restricted for its own shortcomings such as poor material removal rate and high electrode wear ratio etc. In order to overcome this shortcoming, a new piezoelectric self-adaptive micro-EDM (PSMEDM) is developed based on inverse piezoelectric effect of piezoelectric ceramics and its working mechanism and characteristics have been analyzed in this paper. This machining method can realize the self-tuning regulation of discharge gap depending on the discharging conditions, facilitate removing the debris in the machining gap, reduce the occurrence of arcing and shorting and can realize the self-elimination of short circuits, thus the machining efficiency can be improved drastically. The tool electrode wear ratio (EWR) in machining is studied in this paper. Many experiments have been done and the effects of parameters on electrode wear ratio have been analyzed. Experimental results indicate that: 1) The EWR will rise with the increase of open-circuit voltage and main capacitance in circuit because the increase of open-circuit voltage and capacitance result in increase of single discharge energy. 2) The effect of resistance R1 on EWR is light. With the increase of resistance R1, the EWR will decrease slightly. 3) With the increase of resistance R2, the EWR will decrease firstly and then becomes to increase.

Investigation on the Influence of Machining Fluid on Processing Characteristics in Micro-EDM

2012 ◽  
Vol 479-481 ◽  
pp. 407-413 ◽  
Author(s):  
Sha Li ◽  
Wataru Natsu ◽  
Takeshi Masaki ◽  
Zu Yuan Yu
Keyword(s):  
Feed Rate ◽  
Deionized Water ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Machining Speed ◽  
Small Electrode ◽  
Short Circuits ◽  
Edm Drilling

In this paper the influence of machining liquid on the processing characteristics, such as the tool electrode wear and the tool actual feed were discussed. Micro EDM drilling was carried out using deionized water and oil dielectric as the machining liquid. It was found that using deionized water reduced the tool electrode wear. Also, occurrence of short-circuits during the processing is one of the reasons for causing large electrode wear. In the case of using oil dielectric, processed depth influences the tool electrode wear greatly and causes the change in the actual feed rate. While using deionized water, processed depth also causes the change in the actual feed rate, but nearly had no influence on the tool electrode wear. Meanwhile, when using deionized water, although the small electrode wear and high machining speed can be obtained, electrolytic dissolution may occur. Therefore, the effective method of decreasing the open voltage and increasing the feed rate to prevent the electrolytic dissolution was mentioned and experimentally verified.

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.

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

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.

Micro-EDM for an Aluminium Matrix Composite

2010 ◽  
Vol 447-448 ◽  
pp. 233-237 ◽  
Author(s):  
Fu Qiang Hu ◽  
Bo Yan Song ◽  
Ji Cheng Bai ◽  
P.J. Hou ◽  
H.C. Chen ◽  
...  
Keyword(s):  
Matrix Composite ◽  
Open Circuit ◽  
Aluminium Matrix ◽  
Dimensional Structure ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Aluminium Matrix Composite ◽  
The Impact

The silicon carbide particle reinforced aluminium matrix composite (SiCp/Al) which is acknowledged as one of the most competitive metal matrix composites is now widely applied in aviation, aerospace and military fields, and its application is extending gradually. As a result of the hard and brittle SiC particles contained, mechanical machining of the material is difficult, but the method of electric discharge machining (EDM) has certain prominent advantages. In this paper, SiCp/Al was machined using micro-EDM. First, a Ф40μm × 4.1mm micro tool electrode of which the aspect ratio is up to 100 was made; and then, through experiment, the impact of open-circuit voltage and electrode material on processing speed and electrode wear was analyzed; finally, 28μm wide micro slits, micro square platform of 34μm long on each side and other micro three-dimensional structure were machined. Research and experimental results show that the use of appropriate micro-machining parameters and reasonable processing methods can improve processing performance to better achieve the micro-EDM of SiCp /Al.

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.

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