Development of new fabrication and measurement techniques of micro-electrodes with high aspect ratio for micro EDM using typical EDM machine

Hourmand, Mehdi; Sarhan, Ahmed A.D.; Noordin, M.Y.

doi:10.1016/j.measurement.2016.11.020

Cited by 49 publications

(15 citation statements)

References 37 publications

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“…It is observed that for most of the oils, the viscosity inversely varies with rising temperature [36]. During the EDM machining, temperature goes up to 10,000 °C, so the viscosity of all of these substances will change during the machining [25,34]. The comparative study claims that vegetable oils are comparatively denser than conventional paraffin oils.…”

Section: Viscosity Of the Mediummentioning

confidence: 97%

“…On the other hand, various problems are noticed during the traditional machining of ceramic materials. But while EDMed using kerosene as a dielectric medium, it shows expected machining output and high tolerance [32,33] [8] observed that due to resistive effect of silicon particles, the available value of current decreased, which causes rise in spark gap with relatively less dimensional crater CuW WCA16%Co (HS-US16 plate) Hourmand et al [34] concluded that high aspect ratio could be obtained in micro-level machining with reduced machining time if machining is performed using EDM oil as a dielectric medium Copper-tungsten Cu…”

Section: Graphite Powder-mixed Dielectricsmentioning

confidence: 99%

See 1 more Smart Citation

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

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Low removal rate, high power consumption, and dependency on conventional fuels (kerosene as a dielectric) are some premier issues that keep the sustainability index of EDM low, though it has huge acceptability and popularity mostly in aviation sectors and biomedical instrumentation to machine some extensively hard ferrous and nonferrous metal/metal alloys. Besides these, the thermal agitation inside the fusion/machining zone partially burns the dielectrics and tool-workpiece-metal, which evolve some oxides/monoxides. These evolved gases promote an unhygienic breathing atmosphere, which is very much harmful to the operator's health. Sometimes because of inadequate flushing pressure and velocity, carbon particles deposited inside the crater makes the spark unstable and releases carbon monoxide when the temperature exceeds its melting point. According to ISO 14000, every manufacturing process must be comprised of the sustainability criteria, which maintains a compromised balance between the economic, environmental, and social aspects, including the issue of the operator's health. But in real practices, it is very tough to maintain a stoichiometric balance between all these constraints. The article intensely focuses on the issue of emergence of gases during machining and tries to promote the utility of some alternative vegetable oil-based dielectrics, which are experimentally justified as a potent alternative of conventional kerosene. Apart from these, it includes some comparative talks on dielectric nature and their impacts on the responses and surface properties. Finally, this article highlights some compromise solutions which are probably capable of mitigating the hurdles to some extent, so that the sustainable machining can be encouraged in real sense.

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Section: Viscosity Of the Mediummentioning

confidence: 97%

Section: Graphite Powder-mixed Dielectricsmentioning

confidence: 99%

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Das

Paul

Doloi

2020

J Braz. Soc. Mech. Sci. Eng.

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“…Liao et al [ 27 ] reported that it is easier to fabricate single microfeatures using WEDM; however, if the structures are to be produced repeatedly in the form of structure arrays, the process becomes complicated and maintaining feature geometry is difficult. Hourmand et al [ 28 ] used EDM to fabricate a microtool of 4.7 mm length that was used to produce a hole through die-sinking EDM. Zahiruddin et al [ 29 ] reported that thermal deformation occurs in the thin structures produced through WEDM.…”

Section: Introductionmentioning

confidence: 99%

High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM)

et al. 2020

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Thin structures are often required for several engineering applications. Although thick sections are relatively easy to produce, the cutting of thin sections poses greater challenges, particularly in the case of thermal machining processes. The level of difficulty is increased if the thin sections are of larger lengths and heights. In this study, high-aspect-ratio thin structures of micrometer thickness (117–500 µm) were fabricated from D2 steel through wire electrical discharge machining. Machining conditions were kept constant, whereas the structure (fins) sizes were varied in terms of fin thickness (FT), fin height (FH), and fin length (FL). The effects of variation in FT, FH, and FL were assessed over the machining errors (FT and FL errors) and structure formation and its quality. Experiments were conducted in a phased manner (four phases) to determine the minimum possible FT and maximum possible FL that could be achieved without compromising the shape of the structure (straight and uniform cross-section). Thin structures of smaller lengths (1–2 mm long) can be fabricated easily, but, as the length exceeds 2 mm, the structure formation loses its shape integrity and the structure becomes broken, deflected, or deflected and merged at the apex point of the fins.

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“…In recent years, with the emergence of difficult-tocut materials in micro-machinery, various machining technologies like non-traditional machining, [2][3][4] highspeed grinding, 5 and micro-milling 6 have been gradually applied to fabricate the HAR micro-grooves with strict machined quality requirements. Uno et al 7 conducted an experimental study of electrical discharge machining (EDM) forming system of narrow slots using a rotating disk electrode and found that the processing time required of EDM with the rotating disk electrode was shorter than that with a rectangular electrode.…”

Section: Introductionmentioning

confidence: 99%

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

Yang

Han

Hao

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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High aspect ratio micro-grooves are critical structures in the micro-electromechanical system. However, problems like rapid tool wear, low processing efficiency, and inferior machined quality in micro-milling of high aspect ratio micro-grooves by length–diameter ratio tools are particularly significant. In this work, a combined micro-milling method based on water-free alcohol as the cutting fluid and laser deburring is proposed to investigate the high aspect ratio micro-groove generation of oxygen-free high-conductivity copper TU1. Parametric experiments and high aspect ratio micro-groove experiments were conducted to investigate the surface quality, cutting forces, and tool wear. The water-free alcohol was employed to improve the tool life and machined surface quality. In the case of the oxygen-free high-conductivity copper TU1 material, a satisfactory high aspect ratio micro-groove (groove-width = 0.2 μm and aspect ratio = 2.5) with a nanoscale surface roughness ( Ra = 68 nm) was obtained under the preferred machining conditions. Furthermore, the deburring process of the high aspect ratio micro-groove by the laser technology was conducted to achieve ideal machined quality of the top surfaces.

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Development of new fabrication and measurement techniques of micro-electrodes with high aspect ratio for micro EDM using typical EDM machine

Cited by 49 publications

References 37 publications

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM)

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

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