Fabrication of Micro Tool Electrode by Micro EDM using Wear Ratio

2018 ◽  
Vol 27 (1) ◽  
pp. 1-6
Author(s):  
In Yong Moona ◽  
Do Kwan Chung ◽  
Bo Hyun Kim
Keyword(s):  
Tool Electrode ◽  
Micro Edm ◽  
Wear Ratio ◽  
Micro Tool

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.

scholarly journals An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

2017 ◽  
Vol 64 (2) ◽  
pp. 149-163 ◽  
Author(s):  
Govindan Puthumana
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Micro Edm ◽  
Modeling And Analysis ◽  
Micro Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Main Effect

AbstractTo achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a regression relationship between tool wear ratio and the process inputs has been developed.

Experimental Research of Electrochemical Mechanical Polishing (ECMP) for Micro Tool Electrode

2011 ◽  
Vol 314-316 ◽  
pp. 1846-1850 ◽  
Author(s):  
Shuai Guo ◽  
Z.N Guo ◽  
Hong Ping Luo ◽  
Wen Cai Gu
Keyword(s):  
Experimental Research ◽  
Process Parameters ◽  
Mechanical Polishing ◽  
Working Fluid ◽  
Tool Electrode ◽  
Electrical Parameters ◽  
Electrochemical Mechanical Polishing ◽  
Major Process ◽  
Micro Tool ◽  
Quantitative Analyses

The mechanism of the elctrochemical mechanical polishing (ECMP) technology for micro tool electrode was investigated. In this paper, suitable major process parameters on the surface quality were evaluated, the major parameters contains electrical parameters, machining gap, the working fluid and other factors. In quantitative analyses, the process of the ECMP technology were conducted. The roughness of the workpiece was reduced from a relatively high value to a mirror effect.

Effects of tool electrode size on surface characteristics in micro-EDM

2018 ◽  
Vol 96 (9-12) ◽  
pp. 3909-3916 ◽  
Author(s):  
Kan Wang ◽  
Qinhe Zhang ◽  
Guang Zhu ◽  
Jianhua Zhang
Keyword(s):  
Surface Characteristics ◽  
Tool Electrode ◽  
Micro Edm ◽  
Electrode Size

A Study on Micro-tool and Micro-feature Fabrication in Micro-EDM

2019 ◽  
pp. 191-202
Author(s):  
Biswesh Ranjan Acharya ◽  
Abhijeet Sethi ◽  
Akhil Dindigala ◽  
Partha Saha ◽  
Dilip Kumar Pratihar
Keyword(s):  
Micro Edm ◽  
Micro Tool

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.

Research on Side-Insulation of Tool Electrode for Micro Electrochemical Machining

2009 ◽  
Vol 60-61 ◽  
pp. 380-387 ◽  
Author(s):  
Gai Hong Liu ◽  
Yong Li ◽  
Xu Peng Chen ◽  
Shan Jin Lv
Keyword(s):  
Spin Coating ◽  
Electrochemical Machining ◽  
Processing Parameters ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Insulation Material ◽  
Durability Test ◽  
Micro Ecm ◽  
Micro Tool ◽  
Micro Array

In micro electrochemical machining (micro ECM), side-insulation of tool electrode can significantly improve the machining accuracy, especially for high aspect ratio structures. This paper presented a new side-insulation approach for not only micro single electrodes but also micro array electrodes, in which spin-coating and room curing are used to coat the micro tool electrodes with a very thin film of polymer, followed by an end-rubbing process to remove the insulation material from the electrode end surfaces. Processing parameters of spin-coating were optimized experimentally, and side-insulated micro single electrodes with a double-layer epoxy coating of 3m thickness were prepared. Experiments were made to test the performance of the side-insulation film under simulated micro ECM conditions. And the results demonstrated good insulativity and high adherence strength in a 6-hour durability test. Also side-insulation for micro array electrodes was performed using this approach.

Micro-EDM drilling of ZrB2-SiC-graphite composite using micro sheet-cylinder tool electrode

2017 ◽  
Vol 92 (5-8) ◽  
pp. 2033-2041 ◽  
Author(s):  
Huichao Li ◽  
Zhenlong Wang ◽  
Yukui Wang ◽  
Hongzheng Liu ◽  
Yufei Bai
Keyword(s):  
Tool Electrode ◽  
Micro Edm ◽  
Graphite Composite ◽  
Edm Drilling

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.

Migration of Materials during Finishing Micro-EDM of Tungsten Carbide

2010 ◽  
Vol 443 ◽  
pp. 681-686 ◽  
Author(s):  
Muhammad Pervej Jahan ◽  
Mustafizur Rahman ◽  
Yoke San Wong
Keyword(s):  
Tungsten Carbide ◽  
Surface Defects ◽  
Surface Characteristics ◽  
Lower Amount ◽  
Tool Electrode ◽  
Micro Edm ◽  
Tungsten Electrode ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Carbon Migration

Present study aims to investigate the migration of materials onto the surface of workpiece and electrode during fine-finish die-sinking and milling micro-EDM of tungsten carbide using pure tungsten electrode. The effect of materials transfer on the machined surface characteristics is also presented. The machined surfaces have been examined under scanning electron microscope (SEM) and energy dispersive X-ray (EDX) in order to investigate the changes in chemical composition due to the migration of materials. It has been observed that materials from both workpiece and electrode transfer to each other depending on machining conditions and discharge energy. A significant amount of carbon migrates to both electrode and workpiece surface due to the decomposition of dielectric hydrocarbon during breakdown. The migration occurs more frequently at lower gap voltages during finish die-sinking micro-EDM due to low spark gap and stationary tool electrode. Milling micro-EDM suffers from lower amount of carbon migration and fewer surface defects which improve the overall surface finish and reduce surface roughness significantly.

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