New applications for micro-EDM

Fleischer, Jürgen; Masuzawa, Takahisa; Schmidt, Jan Philipp; Knoll, Maximilian

doi:10.1016/j.jmatprotec.2004.02.012

Cited by 110 publications

(52 citation statements)

References 2 publications

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“…It has been successfully employed in aerospace, automobile, and other industries for shaping, cutting, deburring and finishing [36,37]. Due to its complex shape generation it has rapidly earned its place among many nontraditional machining processes.…”

Section: Background and Motivationmentioning

confidence: 99%

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Pattabhiraman

Marla

Kapoor

2015

Volume 1: Processing

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Electrical Discharge Machining is a non-traditional machining process that is widely used in the tool and die-making industry, automotive, and aerospace industries due to its ability to produce complex three-dimensional geometries with good accuracy and surface finish. Despite the aforementioned advantages, the consumption of a large quantity of dielectric (especially hydrocarbon oils) poses a significant health and environmental hazard including respiratory and skin irritation issues. Further, the disposal of waste dielectric that contains a significant amount of metal particulates poses safety concerns. In order to comply with environmental safety standards, extensive filtration and treatment systems capable of handling huge amounts of dielectric waste need to be set up for their safe disposal.This leads to an increased energy consumption and hence higher operating cost for the machining process. Thus, there is a need to reduce the consumption of oil-based dielectrics without compromising their superior machining performance.Several techniques including dry and near-dry EDM have been developed to reduce the consumption of dielectrics. However, they have poor debris flushing capability. This research seeks to develop a technique that minimizes the consumption of dielectrics and also improves the flushing of debris from the inter-electrode gap.A novel method of using atomized dielectric spray in EDM (Spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the inter-electrode gap and acts as a single-phase dielectric medium between the electrodes. It also effectively removes the debris particles from the discharge zone. Single-discharge EDM experiments are performed using ii three different dielectric supply methods, viz., conventional Wet-EDM (electrodes submerged in dielectric medium), Dry-EDM and Spray-EDM in order to compare the processes based on material removal, tool electrode wear and flushing of debris from the inter-electrode gap across a range of discharge energies. It is observed that Spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study.The tool electrode wear using atomized dielectric is significantly better than Dry-EDM and comparable to that observed in Wet-EDM. The percentage of debris particles deposited within a distance of 100 µm from the center of EDM crater is also significantly reduced using the Spray-EDM technique. iv

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Section: Background and Motivationmentioning

confidence: 99%

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Pattabhiraman

Marla

Kapoor

2015

Volume 1: Processing

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“…Volume wear ratio (tool/workpiece) Machinability Cost Best application (Fleischer et al, 2004) www.intechopen.com…”

Section: Electrode Materialsmentioning

confidence: 99%

Micro Eletro Discharge Milling for Microfabrication

Ali¹,

Mehfuz²,

Khan³

et al. 2012

Micromachining Techniques for Fabrication of Micro and Nano Structures

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“…Microelectrical discharge machining (micro-EDM), because of such advantages as contact-less process, no cutting force, low cost, and wide materials suit to fabricate, has been widely applied in the manufacturing of geometrically complex and hard material microstructures. At present, it has been recognized as one of the most valuable techniques for micromachining [1][2][3].…”

Section: Introductionmentioning

confidence: 99%

A New Measurement Method of Relative Volume Wear Ratio Based on Discharge Debris Composition Analysis in Micro-EDM

Liu

Jia

Zou

et al. 2014

Advances in Mechanical Engineering

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In microelectrical discharge machining (micro-EDM) milling process, due to the unavoidability of electrode wear, selection of electrode with high electrical erosion resistance and accurate electrode compensation is entitled to be conducted to ensure high precision and high quality. The RVWR is used as criterion for electrode wear characteristics and is fundamental to achieve accurate electrode compensation; however, it is hardly measured accurately with conventional methods. In this paper, firstly, the error of RVWR measured by conventional measurement method is analyzed. Thereafter, for accurately measuring RVWR, a new measurement method is proposed based on electrical debris composition analysis. The RVWR of widely used tungsten, molybdenum, and copper electrode in machining different materials is measured, respectively, and the optimum electrode is selected based on the measuring results. Finally, microgrooves on different materials are machined with tungsten electrode, and the experiment results show that the microstructures have good bottom surface profiles, which indicates that the proposed method is effective to precisely measure the RVWR and guarantee accurate electrode compensation in micro-EDM process.

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New applications for micro-EDM

Cited by 110 publications

References 2 publications

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Micro Eletro Discharge Milling for Microfabrication

A New Measurement Method of Relative Volume Wear Ratio Based on Discharge Debris Composition Analysis in Micro-EDM

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