Machining Deep Micro Holes by EDM with USM in Inversion Installing

2009 ◽  
Vol 626-627 ◽  
pp. 321-326
Author(s):  
Bao Xian Jia ◽  
D.S. Wang ◽  
Jing Zhe Guo
Keyword(s):  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Structural Features ◽  
Ultrasonic Machining ◽  
Micro Holes ◽  
Exploratory Experiment ◽  
A New Technique ◽  
Working Liquid

In order to obtain micro holes with high aspect ratio, a new technique of machining deep micro holes by combining EDM (Electrical Discharge Machining) with USM (Ultrasonic Machining) in inversion installing is researched. The workpiece is over the electrode. The ultrasonic vibration is affixed to the electrode. The workpiece and electrode are all immersed in working liquid. The debris generated by EDM is dropped out the hole from the gap between the electrode and the hole wall by the gravity and the pumping effect of ultrasonic vibration, so as to increasing the machining velocity and machined depth. The structural features of the machining device are described, and the exploratory experiment is carried out. The corresponding process relations are found out, which can provide references for further study of this technique. The micro holes with larger than 25 in aspect ratio are machined.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Micro Ultrasonic Machining of Ceramic MEMS With Micro Metallic Dies

2003 ◽  
Author(s):  
Yong Yang ◽  
Xiaochun Li
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Brittle Materials ◽  
Ultrasonic Machining ◽  
Ceramic Components ◽  
Micro Parts

Micro ultrasonic Machining (MUSM) is useful for producing micro parts in brittle materials, especially ceramics. By use of suitable micro metallic dies, the efficiency of fabrication can be significantly enhanced. In this study, the LIGA process was used to generate micro nickel dies, which also served as microelectrodes in Die-sinking Electrical Discharge Machining (EDM) to produce micro tungsten dies for MUSM. With these micro metallic dies, micro ceramic components were fabricated.

Fabrication of High-Aspect Ratio Micro Holes on Hard Brittle Materials -Study on Electrorheological Fluid-Assisted Micro Ultrasonic Machining-

2008 ◽  
Vol 389-390 ◽  
pp. 264-270 ◽  
Author(s):  
T. Tateishi ◽  
Nobuhito Yoshihara ◽  
Ji Wang Yan ◽  
Tsunemoto Kuriyagawa
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Brittle Materials ◽  
Electrorheological Fluid ◽  
Machining Accuracy ◽  
Machining Efficiency ◽  
Ultrasonic Machining ◽  
Auxiliary Electrode ◽  
Abrasive Grains ◽  
Micro Holes

Ultrasonic machining (USM) is an effective method for machining of hard brittle materials. In this process, the slurry is supplied to the gap between the workpiece and the ultrasonic vibrating tool, and the materials are removed by the impacts of the abrasive grains that are pressurized by an ultrasonic vibrating tool. The purpose of this research is to achieve precise and efficient microfabrication on hard brittle materials by USM. However, in the case of microfabrication, chipping which is generally observed around the edges of machined micro holes and grooves, deteriorates the machining accuracy. In addition, there is another problem in that the machining efficiency decreases with the progress of the machining. Electrorheological fluid-assisted USM has been proposed as a countermeasure to these problems. In the present study, the problems and countermeasures associated with the machining of high-aspect ratio micro holes in hard brittle materials by electrorheological fluid-assisted USM are investigated. By positioning an auxiliary electrode under the workpiece, it becomes possible to keep the electric field high even when the machining depth becomes large. As a result, high-precision and high-aspect ratio micro holes can be machined on hard brittle materials.

Ultrasonic vibration electrical discharge machining in gas

2002 ◽  
Vol 129 (1-3) ◽  
pp. 135-138 ◽  
Author(s):  
Q.H Zhang ◽  
J.H Zhang ◽  
J.X Deng ◽  
Y Qin ◽  
Z.W Niu
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Electrical Discharge Machining
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