In-situ process monitoring and adaptive control for precision micro-EDM cavity milling

Wang, Jun; Qian, Jun; Ferraris, Eleonora; Reynaerts, Dominiek

doi:10.1016/j.precisioneng.2016.09.001

Cited by 42 publications

(18 citation statements)

References 17 publications

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“…The energy index e is predefined by the manufacturer and is related to the generator capacitance. The wear compensation factor was also adjusted specifically for each energy index e to enable continuous and effective removal of the workpiece material [23,24]. Prior to bioelectrochemical studies, the electrodes were thoroughly cleaned using acetone and deionized water in an ultrasonic bath.…”

Section: Surface Roughness Modification Of Glassy Carbon Electrodesmentioning

confidence: 99%

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

Pierra

Golozar

Zhang

et al. 2018

Bioelectrochemistry

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Bioelectrochemical systems couple electricity demand/supply to the metabolic redox reactions of microorganisms. Generally, electrodes act not only as electron acceptors/donors, but also as physical support for an electroactive biofilm. The microorganism-electrode interface can be modified by changing the chemical and/or topographical features of the electrode surface. Thus far, studies have reported conflicting results on the impact of the electrode surface roughness on the growth and current production of biofilms. Here, the surface roughness of the glassy carbon electrodes was successfully modified at the sub-microscale using micro electrodischarge machining, while preserving the surface chemistry of the parent glassy carbon. All microbial electrodes showed similar startup time, maximum current density, charge transport ability across the biofilm and biomass production. Interestingly, an increase in the average surface cavity depth was observed for the biofilm top layer as a function of the electrode surface roughness (from 7 μm to 16 μm for a surface roughness of 5 nm to 682 nm, respectively). These results indicated that the surface roughness at a sub-microscale does not significantly impact the attachment or current production of mixed culture anodic biofilms on glassy carbon. Likely earlier observations were associated with changes in surface chemistry, rather than surface topography.

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Section: Surface Roughness Modification Of Glassy Carbon Electrodesmentioning

confidence: 99%

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

Pierra

Golozar

Zhang

et al. 2018

Bioelectrochemistry

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“…Figure 3 provides a summary of the operations performed to compute these four quantities, which are considered as potential indicators for the process fingerprint in this research. While f p , f s , and fr are quantities that are conventionally monitored in micro-EDM operations for various purposes such as tool wear compensation [23,24] and breakthrough detection [25,26]. For the purposes of this study, the meaning of Δ u deserves a more detailed explanation.…”

Section: Methodsmentioning

confidence: 99%

Process Fingerprint in Micro-EDM Drilling

2019

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The micro electrical discharge machining (micro-EDM) process is extensively used in aerospace, automotive, and biomedical industries for drilling small holes in difficult-to-machine materials. However, due to the complexity of the electrical discharge phenomena, optimization of the processing parameters and quality control are time-consuming operations. In order to shorten these operations, this study investigates the applicability of a process fingerprint approach in micro-EDM drilling. This approach is based on the monitoring of a few selected physical quantities, which can be controlled in-line to maximize the drilling speed and meet the manufacturing tolerance. A Design of Experiments (DoE) is used to investigate the sensitivity of four selected physical quantities to variations in the processing parameters. Pearson’s correlation is used to evaluate the correlation of these quantities to some main performance and hole quality characteristics. Based on the experimental results, the potential of the process fingerprint approach in micro-EDM drilling is discussed. The results of this research provide a foundation for future in-line process optimization and quality control techniques based on machine learning.

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“…In the finishing machining process, a small amount of material was removed by changing multi-factors of machining parameters. Based on the discharge pulse behavior, Wang et al [ 21 ] combined off-line and in-line adaptive tool wear compensation to achieve effective and efficient tool wear compensation in micro-EDM milling, and prepared hemisphere, cone and pyramid cavities, with good form accuracy on the stainless steel. Tong et al [ 22 ] developed a novel process of 3D servo scanning micro-EDM with the movement of two-axis linkage and one-axis servo, and efficiently and cheaply machined 3D complex micro driving structures pierced through thin-walled micro tube of NiTi SMA.…”

Section: Introductionmentioning

confidence: 99%

Surface Quality Improvement of 3D Microstructures Fabricated by Micro-EDM with a Composite 3D Microelectrode

Lei

Jiang

et al. 2020

Micromachines

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Three-dimensional (3D) microelectrodes used for processing 3D microstructures in micro-electrical discharge machining (micro-EDM) can be readily prepared by laminated object manufacturing (LOM). However, the microelectrode surface always appears with steps due to the theoretical error of LOM, significantly reducing the surface quality of 3D microstructures machined by micro-EDM with the microelectrode. To address the problem above, this paper proposes a filling method to fabricate a composite 3D microelectrode and applies it in micro-EDM for processing 3D microstructures without steps. The effect of bonding temperature and Sn film thickness on the steps is investigated in detail. Meanwhile, the distribution of Cu and Sn elements in the matrix and the steps is analyzed by the energy dispersive X-ray spectrometer. Experimental results show that when the Sn layer thickness on the interface is 8 μm, 15 h after heat preservation under 950 °C, the composite 3D microelectrodes without the steps on the surface were successfully fabricated, while Sn and Cu elements were evenly distributed in the microelectrodes. Finally, the composite 3D microelectrodes were applied in micro-EDM. Furthermore, 3D microstructures without steps on the surface were obtained. This study verifies the feasibility of machining 3D microstructures without steps by micro-EDM with a composite 3D microelectrode fabricated via the proposed method.

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In-situ process monitoring and adaptive control for precision micro-EDM cavity milling

Cited by 42 publications

References 17 publications

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

Process Fingerprint in Micro-EDM Drilling

Surface Quality Improvement of 3D Microstructures Fabricated by Micro-EDM with a Composite 3D Microelectrode

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