Development and Application of a Micro-Honing-Tool

2009 ◽  
Vol 76-78 ◽  
pp. 189-194
Author(s):  
Shun Tong Chen ◽  
Ming Chie Yeh
Keyword(s):  
Surface Roughness ◽  
Hole Drilling ◽  
Micro Edm ◽  
Wire Edm ◽  
Uneven Surface ◽  
Novel Technique ◽  
New Process ◽  
Micro Hole ◽  
Micro Tool ◽  
On Line

The major aim of this study is to present a novel technique for honing the micro-hole. It is difficult that regarding the finish machining of the micro-hole that the diameter is less than 300 m. First, a new process that to on-line accurately fabricate the micro-honing-tool using micro-EDM, micro-co-deposition and micro-wire-EDM is proposed for honing the micro-hole. A micro rod for as the substrate of the micro-tool is formed by wire-EDM and then co-deposited with 0-2 m CBN-abrasives. Subsequently, it is axially and crisscross cut for an appropriate length by micro-wire-EDM to make the crotched microstructure. The whole processes are able to be on-line realized since all working positions are recorded in detail and fabrication technologies are offered sufficiently on the same system. As a result, per the same fabrication-system, the micro-honing process is also on-line conducted. The finished micro-honing-tool is employed directly without unloaded and reloaded. The grinding-block can compactly stick on the wall surface of the micro-hole due to the radial elasticity of the micro-tool and then fast grind away the uneven surface by removal of micro amount. Experimental results demonstrated that the circularity and surface roughness on the hole-wall is evidently improved. Comparing with the obtained machining surface by micro-EDM hole-drilling, the original surface roughness of near one-sixth time can be achieved. It is indicated that the micro-hole can be honed accurately using the proposed technique.

scholarly journals Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool

Micromachines ◽  
2020 ◽  
Vol 11 (7) ◽  
pp. 675 ◽  
Author(s):  
Yung-Yi Wu ◽  
Tzu-Wei Huang ◽  
Dong-Yea Sheu
Keyword(s):  
Aspect Ratio ◽  
Large Scale ◽  
Cemented Carbide ◽  
Hole Drilling ◽  
Scale Production ◽  
Micro Edm ◽  
Micro Holes ◽  
Micro Hole ◽  
Micro Tool ◽  
Micro Tools

Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15.

scholarly journals Surface Texture of Titanium 31 and H.S.S using Micro EDM Drill and Wire EDM

2019 ◽  
Vol 8 (9) ◽  
pp. 262-266
Keyword(s):  
Surface Roughness ◽  
Surface Texture ◽  
Sem Analysis ◽  
Dielectric Fluid ◽  
Micro Edm ◽  
Wire Edm ◽  
Electronic Microscope

Micro EDM Drill is variant EDM processes in a situation where it employs water as a dielectric fluid, with pressure flushing and rotating nanotube electrode. This paper brings out the relative features of work pieces i.e., H.S.S and Titanium 31 about their surface roughness with Talysurf, as well as Surfaces Texture with Scanning Electronic Microscope (SEM analysis).Thus the results are evaluated for Ra (Surface Roughness), Rsk (Surface Skewness) and Rku (Surface Kutosis).

High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM

CIRP Annals ◽  
2009 ◽  
Vol 58 (1) ◽  
pp. 213-216 ◽  
Author(s):  
Z.Y. Yu ◽  
Y. Zhang ◽  
J. Li ◽  
J. Luan ◽  
F. Zhao ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
High Aspect Ratio ◽  
Hole Drilling ◽  
Micro Edm ◽  
Micro Hole

On-Line Fuzzy Monitoring of Micro-Hole Drilling Based on Genetic Algorithm

2012 ◽  
Vol 184-185 ◽  
pp. 1588-1591
Author(s):  
Hui Meng Zheng ◽  
Jian Qing Chen ◽  
Shou Xin Zhu
Keyword(s):  
Genetic Algorithm ◽  
Fuzzy Control ◽  
Production Costs ◽  
Hole Drilling ◽  
Drill Bit ◽  
Bit Wear ◽  
Micro Hole ◽  
On Line ◽  
Drilling System ◽  
Spindle Current

In automated micro-hole drilling system, in order to improve the drilling performance and reduce of production costs by maximizing the use of drill life and preventing drill failures, the drill bit wear state monitoring is more important. However, drill bit wear is difficult to measure in drilling process. By observation, wear failure of the drill bit could cause related changes of the spindle current signal, so construct fuzzy control mathematical models with the relationship between drill bit wear and spindle current, genetic algorithm and fuzzy control theory are applied to micro-drilling system in this paper .The membership functions of fuzzy control model are optimized by genetic algorithms. Through calculation, we can get drill bit wear value which used as monitoring threshold value in micro-hole drilling on-line monitoring system to avoid the drill breakage and improve the monitoring reliability.

Fabrication of a micro-tool in micro-EDM combined with co-deposited Ni–SiC composites for micro-hole machining

2007 ◽  
Vol 17 (4) ◽  
pp. 763-774 ◽  
Author(s):  
Jung-Chou Hung ◽  
Wei-Chieh Wu ◽  
Biing-Hwa Yan ◽  
Fuang-Yuan Huang ◽  
Kun-Ling Wu
Keyword(s):  
Micro Edm ◽  
Micro Hole ◽  
Micro Tool ◽  
Sic Composites ◽  
Hole Machining

Study on Machining Characteristics of Ultrasonic Vibration Assisted Micro-EDM

2012 ◽  
Vol 217-219 ◽  
pp. 2163-2166 ◽  
Author(s):  
Tomohiko Ichikawa ◽  
Wataru Natsu
Keyword(s):  
Ultrasonic Vibration ◽  
Machining Process ◽  
Hole Drilling ◽  
Micro Edm ◽  
Discharge Energy ◽  
Machining Speed ◽  
Micro Hole ◽  
Short Circuits ◽  
Small Discharge ◽  
Machining Characteristics

The existence of debris in the inter-electrode area in micro-EDM interrupts the machining process. Applying ultrasonic vibration to the machining fluid helps circulate the machining fluid and remove the debris from the gap area, and thus reduce short-circuits and abnormal discharges. In this study, the effect of applying ultrasonic vibration to machining fluid in micro-EDM was experimentally investigated. It was found that a significant increase in the machining speed was realized by applying ultrasonic vibration. Also, with the vibration of the machining fluid, micro-hole drilling with ultra-small discharge energy became possible.

Study on the Fuzzy Control System of Micro-Hole Drilling

2012 ◽  
Vol 580 ◽  
pp. 126-129 ◽  
Author(s):  
Hui Meng Zheng ◽  
Dong Hui Wang
Keyword(s):  
Control System ◽  
Fuzzy Control ◽  
Fuzzy Controller ◽  
Hole Drilling ◽  
Monitoring Systems ◽  
Work Piece ◽  
Drill Bit ◽  
Control Technology ◽  
Micro Hole ◽  
On Line

To improve the accuracy and reliability of control system ,we construct a set of micro-hole drilling on-line monitoring systems based on fuzzy control technology. The axial force and torque collected from experiment are inputted to fuzzy controller get the real-time wear state of drill bit. Then compare the wear value with monitoring threshold, if the amount is bigger than the threshold, the system will alarm and retract the cutter, so the drill can avoid be broken and work piece be saved.

Micro-Hole Drilled by EDM-ECM Combined Processing

2013 ◽  
Vol 562-565 ◽  
pp. 52-56 ◽  
Author(s):  
Xiao Long He ◽  
Yu Kui Wang ◽  
Zhen Long Wang ◽  
Zhao Qi Zeng
Keyword(s):  
Mechanical Property ◽  
Surface Defects ◽  
Dielectric Medium ◽  
Recast Layer ◽  
Hole Drilling ◽  
Machining Efficiency ◽  
Micro Edm ◽  
Shape Accuracy ◽  
Micro Ecm ◽  
Micro Hole

A new method for drilling micro-hole called EDM-ECM combined processing is proposed in this paper. This method consists of EDM shaping and ECM finishing, and they are carried out in sequence on the same machine tool with the same electrode but different dielectric medium. Micro-hole drilling experiment was done by micro-EDM, micro-ECM and EDM-ECM combined processing. The results show that the machining efficiency is improved by 9.2 times compared to conventional micro-ECM, and machining precision and shape accuracy of micro-hole are much better. The surface quality and mechanical property of the workpiece are improved, since the recast layer and surface defects generated by EDM are removed completely by ECM finishing. It proves that this combined machining method is possible and useful in the field of micro-hole drilling.

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