High-Speed and High-Accuracy EDM of Micro Holes by Using a 5-DOF Controlled Maglev Local Actuator

Abstract

The objective of this study is to realize high-speed and high-accuracy electrical discharge machining (EDM) of micro holes using a combination of a conventional EDM machine and a maglev local actuator. In this paper, the conventional EDM machine and the wide-bandwidth, high-precision, 5-DOF controlled maglev local actuator are combined and cooperatively controlled. Then to accelerate the debris ejection from the machined holes, the driving methods of the axial jump and radial vibration of the electrode are discussed. The experimental results show that the maglev local actuator can adjust the gap between the electrode and a workpiece speedily, and the machining speed is improved by 434.2%, compared with conventional EDM machine. Moreover, by the jump and the circular motion of the electrode, the debris ejection can be accelerated, the abnormal electrical discharge can be avoided, and the machining speed also is improved by 580.3%.

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

“…The test results on their system show that with a very low tool wear rate, machining speed and positioning accuracy are greatly improved. By incorporating a high-speed maglev actuator arm with µ-EDM, Zhang et al 8 improved machining speed and precision. In comparison to conventional EDM, the maglev actuator arm increased machining speed by 434.2% compared to conventional EDM.…”

“…By incorporating a high-speed maglev actuator arm with m-EDM, Zhang et al 8 improved machining speed and precision. In comparison to conventional EDM, the maglev actuator arm increased machining speed by 434.2% compared to conventional EDM.…”