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.

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.

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.

Study on Micro Growth Process and Characteristics of Deposited Material in Micro EDM Deposition

2011 ◽  
Vol 697-698 ◽  
pp. 182-186
Author(s):  
Zi Long Peng ◽  
Yi Nan Li ◽  
Z.L. Wang
Keyword(s):  
Growth Process ◽  
Pulse Discharge ◽  
Hardness Test ◽  
Deposition Process ◽  
Tool Electrode ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Initial Stage ◽  
Fine Surface ◽  
Micro Structures

The micro growth process and characteristics of deposited material in micro EDM deposition are researched in this paper. In the initial stage of the deposition the deposited material is not an even layer in the diameter direction of tool electrode. The emergence of deposited material will affect the next pulse discharge distribution between tool electrode and workpiece. A micro cylinder with the diameter of 85µm, height of 255µm formed successfully with the fine surface quality using the tool electrode diameter of 200µm. It has shown that micro EDM deposition process has the ability to fabrication more finer micro structures with thinner electrode. The characteristics of deposited material including bonding behavior between deposited material and workpiece, energy spectrum analysis, hardness test and resist compression test of the deposited material have been tested. Results show that the deposited material has compact microstructure and bonds close to the workpiece, which can be used in the occasion of withstanding compress.

Study on the Characteristics of Discharge Waveform in Micro EDM Deposition Process

2011 ◽  
Vol 697-698 ◽  
pp. 187-191
Author(s):  
Zi Long Peng ◽  
Yi Nan Li ◽  
Z.L. Wang
Keyword(s):  
Short Pulse ◽  
Short Circuit ◽  
Deposition Process ◽  
Pulse Interval ◽  
Process Conditions ◽  
Tool Electrode ◽  
High Deposition Rate ◽  
Micro Edm ◽  
Discharge Energy ◽  
Pulse Generators

Based on the analysis of micro electrical discharge machining (micro EDM) principle, the process conditions of micro EDM deposition has been obtained. Micro EDM deposition is a new EDM method, in which the process conditions includes selecting air as working medium, short pulse duration, long pulse interval, low discharge current and setting the tool electrode as anode. In micro EDM deposition experiments, two types pulse generators of transistor type and RC type are applied respectively. The characteristics of discharge waveforms using each type pulse generator are researched. Results show that both two types pulse generators can be applied in the micro EDM deposition process. The transistor type is easy to obtain the same single discharge energy, but short circuit will damage the deposited material. While RC type can adjust discharge energy according to the discharge gap state, which is well used in micro EDM deposition process with the high deposition rate.

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.

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.

Numerical and Experimental Study on Micro-Electrical Discharge Micromachining Characteristics on Molybdenum

2005 ◽  
Author(s):  
Phil Allen ◽  
Xiaolin Chen ◽  
Dave Kim
Keyword(s):  
Numerical Model ◽  
Electrical Discharge ◽  
High Energy ◽  
Spark Discharge ◽  
Discharge Process ◽  
Micro Edm ◽  
Micron Size ◽  
Mechanical And Physical Properties ◽  
Machining Characteristics ◽  
Edm Process

Electrical discharge micromachining (micro-EDM) is an ideal process for obtaining burr-free machined micron-size apertures. Molybdenum is one of the most attractive high energy and power aperture materials due to its mechanical and physical properties, mainly its high melting temperature and relatively high thermal conductivity. In this paper, fundamental machining characteristics for micro-EDM of molybdenum were investigated both numerically and experimentally. A thermo-numerical model was created to simulate a single spark discharge process. Experimental crater size is investigated using scanning electron microscopy and optical evaluation methods. The effects of important EDM parameters such as the pulse duration on crater shape, temperature distribution, tool wear percentage, and eroded volume were studied. Correlations between numerical and experimental data are also discussed. The model effectively estimates the size of single spark craters in molybdenum. The results show that the developed thermo-numerical model can be an effective tool in predicting the size of a crater formed by a single spark discharge in the micro-EDM process.

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.

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.

Sign in / Sign up

Export Citation Format

Share Document