Electrical discharge machining (EDM) is one of the most accurate methods for machining conductive materials and has a number of important applications. In the EDM process the occurrence of electric charges between cathode and anode is accompanied by vibroacoustic signals, which can be used to develop highly efficient control and diagnostics systems. Experimental studies and modelling of the dynamic system of the EDM process carried out in this study show that parameters of acoustic signals can be used to estimate the current productivity and risks of the tool-electrode breakage and to optimize the tool feed rate. The obtained results of allows using acoustic signals in the control system of the tool electrode feed rate to prevent its breakage, and also setting the interelectrode gap to maximum productivity.
We present a new method for coating deposition on micro cutters without an increase in their cutting edges radii caused by the deposition. For this purpose, the cutting edges are sharpened before the coating deposition with a concentrated beam of fast argon atoms. The sharpening decreases the initial radius and, hence, limits its value after the coating deposition. The concentrated beam of fast argon atoms is generated using an immersed in the gas discharge plasma concave grid under a negative high voltage. Ions accelerated from the plasma by the grid pass through the grid holes and are concentrated in the focal point of the grid. As a result of the charge exchange in the space charge sheaths of the grid, they are transformed into fast atoms. A uniform sputtering by the fast atoms of the micro-cutter surface reduces the radius of its cutting edge.
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