Debris and consequences in micro electric discharge machining of micro-holes

Ekmekçi, Bülent; Sayar, Atakan

doi:10.1016/j.ijmachtools.2012.10.003

Cited by 52 publications

(26 citation statements)

References 17 publications

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“…It was found that the most important factor of the electrode regarding MRR was the electrode material electrical conductivity, while, for TWR, the most important factor was a combination of the grain size and electric resistance. Furthermore, Ekmekci and Sayar [185] studied the origin of concavity at the end-tip in the micro-EDM of blind micro-holes. The shape of tip deformation was investigated experimentally.…”

Section: Electrode Materials and Shape In The Edm Of Tool Steelmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

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Section: Electrode Materials and Shape In The Edm Of Tool Steelmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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“…3, it is known that the center of the micro-cavity processed by microelectrode gradually appeared lug boss structure (Fig. 3b, c, d, e, f) with the voltage increasing from 80 to 130 V. For the lug boss structure, B. Ekmekci et al believed that it was caused by the accumulation of electrode wear [16]. Through a large number of experiments, B. Ekmekci et al have found that micro-electrodes would produce wear during the micro-EDM, and the wear would be deposited on the surface of the micro-structure.…”

Section: The Impact Of Voltage On Micro-edm Resultsmentioning

confidence: 96%

Laminated fabrication of 3D queue micro-electrode and its application in micro-EDM

Lei

Cheng

et al. 2015

Int J Adv Manuf Technol

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3D micro-electrode used in micro electrical discharge machining (micro-EDM) is difficult to be fabricated. Based on laminated object manufacturing (LOM) process, this paper superimposed multilayer 2D micro-structures together to fit out 3D micro-electrode and applied it in micro-EDM to process 3D micro-cavity mold. Firstly, 100-μm-thick Cu foils were cut by wire-electrical discharge machining (WEDM) to obtain multilayer 2D micro-structures, and then these 2D micro-structures were connected together to fit out 3D micro-electrode through vacuum pressure thermal diffusion welding. Secondly, under the effect of 80-V voltage, 0.2-MHz pulse frequency, 800-ns pulse width, and 4200-ns pulse interval, the 3D micro-electrode was applied in micro-EDM and 3D micro-cavity mold with high surface quality was obtained. Thirdly, in order to reduce the adverse impact of electrode wear on machining precision of 3D micro-cavity mold, 3D queue micro-electrode was used to process the same 3D micro-cavity mold, in which the first electrode is for rough machining and the others for fine machining. Finally, based on the above studies, two kinds of 3D queue micro-electrodes were fabricated, and the 3D micro-cavity molds with surface roughness Ra=0.48 μm were obtained through micro-EDM. Compared with the scanning 3D micro-EDM process, the 3D micro-cavity mold can be obtained through up and down reciprocating method of the 3D queue micro-electrode, featuring simple machining process and high efficiency.

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“…Apart from discharge energy, dielectric flushing pressure, debris movement and spark gap also account for a major influence on process performance [25] [26]. 6 Therefore, in this work gap voltage, capacitance and threshold were taken as the machining parameters.…”

Section: Experimentationmentioning

confidence: 99%