Micro-EDM Milling of Micro Platinum Hemisphere

Hang, Guanrong; Cao, Guanghui; Wang, Zaicheng; Tang, Jing; Wang, Zhenlong; Zhao, Wansheng

doi:10.1109/nems.2006.334849

Cited by 8 publications

(5 citation statements)

References 7 publications

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“…After machining every layer, the machine coordinate is noted, and the tool's shape is then determined by bringing the tool to a predetermined fixed point. The platinum micro hemisphere was machined to a diameter of 100

m by Hang et al [ 108 ]. The longitudinal tool wear compensation coordinates were collected from the dynamic interaction of the electrode with a machined hole and predetermined point source.…”

Section: Some Other Monitoring and Compensation Methodsmentioning

confidence: 99%

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

Nadda,

Nirala,

Singh

et al. 2024

Heliyon

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m by Hang et al [ 108 ]. The longitudinal tool wear compensation coordinates were collected from the dynamic interaction of the electrode with a machined hole and predetermined point source.…”

Section: Some Other Monitoring and Compensation Methodsmentioning

confidence: 99%

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

Nadda,

Nirala,

Singh

et al. 2024

Heliyon

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“…Now by substituting equations ( 13), (14), and (15) into equation (12), the shape of the channel in subsequent passes is predicted. Furthermore, using the calculated volume of TW and the experimental value of TWR for a given machining condition, the machining time t for each pass is estimated as…”

Section: Simulations For Subsequent Passesmentioning

confidence: 99%

“…The shapes of the channel in subsequent passes are obtained from equation (12). The variations of the…”

Section: Channel Shape In Subsequent Passesmentioning

confidence: 99%

“…Over the years, different types of mEDM technologies [8,9] have been developed and used for micromanufacturing. Among these types, the micro electric discharge milling (mED-milling) [10][11][12] technique is used for machining complex three-dimensional (3D) features in difficult-to-machine materials. In mEDmilling, a simple cylindrical tool is made to move along a predefined path to machine 3D shapes similar to conventional milling.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Simulation and experimental realization of μ-channels using a μED-milling process

Karthikeyan

Sambhav

Ramkumar

et al. 2011

Proceedings of the Institution of Mechanical Engineers, Part B:

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Machining of microchannels (µ-channels) on hard conducting materials can be performed effectively using a micro electric discharge milling (µED-milling) process. The method of bulk machining is considered in this work, as it takes less machining time than conventional layer-by-layer machining. However, the tool wear in this method occurs both in the side and bottom of the tool, which causes dimensional inaccuracy. Hence, to achieve the desired µ-channel shape, the technique of multiple-pass machining is introduced, wherein a dressed tool is used in each pass to compensate tool wear. The basic idea behind the work is to compute the number of passes and machining time required in achieving the shape. A computer-aided design-based algorithm is used to simulate the shape of the µ-channel and tool for a single pass and for further multiple passes. At the end of each pass, the volume of material removal and tool wear are estimated quantitatively. The desired channel shape is considered to be achieved when the volume of the material left-out is less than or equal to 5 per cent of the ideal volume to be removed. This paper elaborates on the procedure for single- and multiple-pass simulation to determine the number of passes and machining time. The results are validated with experiments for the desired µ-channel shape.

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“…Furthermore, new hybrid processes relying partly on micro-EDM have also evolved [80,81]. The ease of applying EDM as a micro-machining technique has led to the development of various types of micro-EDM processes such as die-sinking [82,83], drilling [84,85], milling [86,87], wire cutting [88,89], wire grinding [53] and turning [90]. However, the commercial application of these processes have so far been confined to niche areas, such as the drilling of high aspect ratio micro-holes for inkjet nozzles [91], tapered holes for diesel fuel injection nozzles [92] and the fabrication of micro-moulds for mass replication processes [93,94].…”

Section: Application Of Edm In Micro-machiningmentioning

confidence: 99%

Advancing the micro-EDM technique with powder-mixed dielectric and process modelling

Tan¹

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The electrical discharge machining (EDM) process possesses inherent characteristics that make it a promising micro-machining technique. However, micro electrical discharge machining (micro-EDM) is only used in niche applications due to the lack of an established knowledge base to facilitate process planning. The stochastic nature of material removal, sensitivity of process performance to process parameters and conditions and numerous process parameter permutations available for machining contribute to the difficulties in building a knowledge base for micro-EDM. Compounding to this complication, the process parameters and conditions in EDM and micro-EDM are distinctly different, thereby rendering limited transferability of knowledge base. Thus, focused studies on micro-EDM are needed to improve process reliability and controllability as well as to enhance process capabilities. This research has endeavoured to achieve advancement of the micro-EDM technique through a two-pronged approach of process performance enhancement and process modelling. The proposed use of powder-mixed dielectric in micro-EDM (PMD micro-EDM) is a novel initiative to adopt this established technological development in EDM (PMD-EDM) for micro-EDM. By reproducing the effects of improved machined surface quality and enhanced machined surface functional properties of PMD-EDM in PMD micro-EDM, advancements to the micro-EDM process has been achieved. The realisation of PMD micro-EDM has been achieved through employing discharge energies less than 25 µJ with sub-microsecond pulse on time durations and complemented by the use of nanopowder additives of semi-conductive and non-conductive materials in concentrations below 1 g/l. Initial investigations on the unit removal characteristics of PMD micro-EDM have shown a distinct difference in the morphology of craters produced in a powder-free and powder-mixed dielectric, thereby proving the feasibility of PMD micro-EDM. Furthermore, the observation of craters having smaller peak-to-valley heights when generated under single electrical discharge conditions has been exhibited as reductions in arithmetical mean surface roughness of 14 % to 24 % when processing with PMD micro-EDM. Improvements in machined surface quality have also been displayed through reductions in recast layer thickness of between 15 % and 35 %.

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Micro-EDM Milling of Micro Platinum Hemisphere

Cited by 8 publications

References 7 publications

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

An overview of techniques for monitoring and compensating tool wear in micro-electrical discharge machining

Simulation and experimental realization of μ-channels using a μED-milling process

Advancing the micro-EDM technique with powder-mixed dielectric and process modelling

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