A novel servo-stabilized electromagnetic levitation formicro-EDM processing and its feasibility analysis

Abstract

The purpose of this paper is to evaluate the feasibility of a novel gap-controlled strategy for micro-EDM process using magnetic levitation. The tool is levitated and positioned accurately using a unique actuator arm. The actuator arm attained the required positioning accuracy in the thrust (Z) direction to ensure a uniform and smooth discharge free of arcing and short circuits. Experiments were carried out using a copper tool and EDM oil on Nimonic superalloy (Grade C-263). Material removal rate (79.26 µg/min), tool wear rate (19.75 µg/min), and average surface roughness (Ra = 1.196 µm) all proved the efficacy of the developed technology. Furthermore, the machining stability and average specific energy (1.7350 J/μg) were examined and compared to the experimental results of traditional EDM, as well as literature data. Maglev μ-EDM is substantially more stable than traditional EDM, according to a comparison of the current-voltage (V-I) curve. Microholes, micropores, recast layer, and other surface topographical features are detected in a low amount using FESEM. The bidirectional material movement and elemental diffusion are shown by elemental characterization using EDX analysis.

Short review on the development of electrical discharge machine

“…Pure DC power may be a good option for facilitating the essential discharge energy in the spark gap because it is free from disturbance and attenuation (noise). Researchers have employed DC power source directly to perform the EDM and achieved significantly higher material removal rate compared to the conventional power supply [30].…”