Electrodischarge Drilling of Microholes in c-BN

Wyszyński, Dominik; Bizon, Wojciech; Miernik, Krzysztof

doi:10.3390/mi11020179

Cited by 9 publications

(6 citation statements)

References 17 publications

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“…It is mainly used for high-precision processing of difficult-to-cut materials. Wyszynski et al [ 14 ] realized the high-precision micro-hole machining of cubic boron nitride and determined the optimal parameters. Wu et al [ 15 ] developed a cut-side micro-tool suitable for the micro-EDM system and successfully realized the deep and high aspect ratio micro-holes machining on tungsten cemented carbide.…”

Section: Introductionmentioning

confidence: 99%

Processing Characteristics of Micro Electrical Discharge Machining for Surface Modification of TiNi Shape Memory Alloys Using a TiC Powder Dielectric

Zhu

Guo

et al. 2020

Micromachines

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Titanium-nickel shape memory alloy (SMA) has good biomedical application value as an implant. Alloy corrosion will promote the release of toxic nickel ions and cause allergies and poisoning of cells and tissues. With this background, surface modification of TiNi SMAs using TiC-powder-assisted micro-electrical discharge machining (EDM) was proposed. This aims to explore the effect of the electrical discharge machining (EDM) parameters and TiC powder concentration on the machining properties and surface characteristics of the TiNi SMA. It was found that the material removal rate (MRR), surface roughness, and thickness of the recast layer increased with an increase in the discharge energy. TiC powder’s addition had a positive effect on increasing the electro-discharge frequency and MRR, reducing the surface roughness, and the maximum MRR and the minimum surface roughness occurred at a mixed powder concentration of 5 g/L. Moreover, the recast layer had good adhesion and high hardness due to metallurgical bonding. XRD analysis found that the machined surface contains CuO2, TiO2, and TiC phases, contributing to an increase in the surface microhardness from 258.5 to 438.7 HV, which could be beneficial for wear resistance in biomedical orthodontic applications.

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Section: Introductionmentioning

confidence: 99%

Processing Characteristics of Micro Electrical Discharge Machining for Surface Modification of TiNi Shape Memory Alloys Using a TiC Powder Dielectric

Zhu

Guo

et al. 2020

Micromachines

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show abstract

“…For example, structures with micro holes have been used to aid cooling in aeronautical engine components such as turbine blades. Presently, various micro-machining methods, such as micro mechanical drilling, laser drilling, electrochemical drilling (ECD) and micro-electrical discharge machining (micro-EDM) have been adopted to machine micro-holes [ 5 , 6 , 7 , 8 ]. However, each method has its limitations in cost, machining efficiency, properties of the workpiece and aspect ratio of a micro-hole [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Precision EDM of Micron-Scale Diameter Hole Array Using in-Process Wire Electro-Discharge Grinding High-Aspect-Ratio Microelectrodes

et al. 2020

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Micro-electrical discharge machining (micro-EDM) is a good candidate for processing micro-hole arrays, which are critical features of micro-electro-mechanical systems (MEMS), diesel injector nozzles, inkjet printheads and turbine blades, etc. In this study, the wire vibration of the wire electro-discharge grinding (WEDG) system has been analyzed theoretically, and, accordingly, an improved WEDG method was developed to fabricate micron-scale diameter and high-aspect-ratio microelectrodes for the in-process micro-EDM of hole array with hole diameter smaller than 20 μm. The improved method has a new feature of a positioning device to address the wire vibration problem, and thus to enhance microelectrodes fabrication precision. Using this method, 14 μm diameter microelectrodes with less than 0.4 μm deviation and an aspect ratio of 142, which is the largest aspect ratio ever reported in the literature, were successfully fabricated. These microelectrodes were then used to in-process micro-EDM of hole array in stainless steel. The effects of applied voltage, current and pulse frequency on hole dimensional accuracy and microelectrode wear were investigated. The optimal processing parameters were selected using response–surface experiments. To improve machining accuracy, an in-process touch-measurement compensation strategy was applied to reduce the cumulative compensation error of the micro-EDM process. Using such a system, micro-hole array (2 × 80) with average entrance diameter 18.91 μm and average exit diameter 17.65 μm were produced in 50 μm thickness stainless steel sheets, and standard deviations of hole entrance and exit sides of 0.44 and 0.38 μm, respectively, were achieved.

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“…In order to process micro-holes on tungsten carbide plates, D'Urso et al [15] applied tubular electrodes in micro-EDM and evaluated the influence of variable process parameters on process performance. For achieving high precision machining of cubic boron nitride, Wyszynski et al [16] described an application of EDM for drilling micro holes in cubic boron nitride and determined a set of parameters and technical specifications. Focus on the fabrication of deep micro-channels, Ahmed et al [17] used wire-cut electrical discharge machining (EDM) to fabricate deep micro-channels with thin inter-channels fins.…”

Section: Introductionmentioning

confidence: 99%

Applying Foil Queue Microelectrode with Tapered Structure in Micro-EDM to Eliminate the Step Effect on the 3D Microstructure’s Surface

Guo

Zhu

et al. 2020

Micromachines

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When using foil queue microelectrodes (FQ-microelectrodes) for micro electrical discharge machining (micro-EDM), the processed results of each foil microelectrode (F-microelectrode) can be stacked to construct three-dimensional (3D) microstructures. However, the surface of the 3D microstructure obtained from this process will have a step effect, which has an adverse effect on the surface quality and shape accuracy of the 3D microstructures. To focus on this problem, this paper proposes to use FQ-microelectrodes with tapered structures for micro-EDM, thereby eliminating the step effect on the 3D microstructure’s surface. By using a low-speed wire EDM machine, a copper foil with thickness of 300 μm was processed to obtain a FQ-microelectrode in which each of the F-microelectrodes has a tapered structure along its thickness direction. These tapered structures could effectively improve the construction precision of the 3D microstructure and effectively eliminate the step effect. In this paper, the effects of the taper angle and the number of microelectrodes on the step effect were investigated. The experimental results show that the step effect on the 3D microstructure’s surface became less evident with the taper angle and the number of F-microelectrodes increased. Finally, under the processing voltage of 120 V, pulse width of 1 μs and pulse interval of 10 μs, a FQ-microelectrode (including 40 F-microelectrodes) with 10° taper angle was used for micro-EDM. The obtained 3D microstructure has good surface quality and the step effect was essentially eliminated.

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Electrodischarge Drilling of Microholes in c-BN

Cited by 9 publications

References 17 publications

Processing Characteristics of Micro Electrical Discharge Machining for Surface Modification of TiNi Shape Memory Alloys Using a TiC Powder Dielectric

Processing Characteristics of Micro Electrical Discharge Machining for Surface Modification of TiNi Shape Memory Alloys Using a TiC Powder Dielectric

Precision EDM of Micron-Scale Diameter Hole Array Using in-Process Wire Electro-Discharge Grinding High-Aspect-Ratio Microelectrodes

Applying Foil Queue Microelectrode with Tapered Structure in Micro-EDM to Eliminate the Step Effect on the 3D Microstructure’s Surface

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