An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-w... more An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-water) and an ECM polishing hybrid with alumina powder of 1.0 μm grains on a single micro-EDM machine are proposed. The process adopts tungsten carbide as tool electrode and M-333 tool steel as the mold material. It reveals that employing the 30 μm/min feed rate with 50 mA and 0.2 ms of pulse-width is suitable for DI-water electrochemical machining. The DI-water ECM process can achieve an excellent surface roughness at Ra 0.169 µm on a semispherical round cavity. Combining the ECM with hybrid polishing with the alumina powder can achieve a better profile for a much deeper cavity than pure electrolytic discharge machining. The hybrid ECM polishing can efficiently finish a micro square insert of 0.6 mm length at 64 μm depth. Such ECM milling can achieve an S-shaped microchannel of radius 1.0 mm and a slot of 1.0 × 0.5 mm2 with 110 μm depth, demonstrating its feasibility and the surface inte...
Owing to its low removal rate and debris ejection nature, EDM is a very slow machining process. A... more Owing to its low removal rate and debris ejection nature, EDM is a very slow machining process. A novel jump motion control for electrode in electrical discharge machining (EDM) equipped with dual linear motors (LmEDM) was proposed to release this debris efficiency point. The direct drive EDM and a novel pulse discriminator were developed. By introducing the discriminator to count effective discharge pulses, an EDM jump control was proposed. Experiments for verification of the EDM efficiency were conducted for 35 mm deep and thin EDM processes with 2 mm thin platelet. EDM efficiency of proposed jump control is verified to be four times over the traditional EDM.
ASME 2012 International Manufacturing Science and Engineering Conference, 2012
ABSTRACT Conventional micro EDM milling relies on time-consuming WEDG to achieve acceptable quali... more ABSTRACT Conventional micro EDM milling relies on time-consuming WEDG to achieve acceptable quality of micro tools. In this study, a rotational axis augmented to Wire Electrical Discharge Grinding (WEDG) processes with ultrasonic assistance and its application to EDM micro-milling is reported. On its removing mechanism, a quantitative analysis based upon wire-EDM discharge-angle was proposed to clarify fundamental understanding of such a novel multi-axial machining process. Then, a test on EDM micro-milling with 70 microns of diameter tool is conducted. Its significant effects on improving dressing efficiency and surface integrity of micro tools were verified, and the effectiveness for EDM micro-milling with a screw type of tool was also verified experimentally. Because of its geometric properties, the screw surface contributed to deliver debris from machining region to outsider. Therefore, a better EDM micro-milling configuration may be introduced into the micro-EDM manufacturing field.
A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-hole... more A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 m in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70oC of water to reveal the final product—a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper ...
Journal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers - Series C
A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-hole... more A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 pm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70 degrees C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery withou...
Journal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers - Series C
A novel pulses discriminator for linear motors direct-drive electrical discharge machining and a ... more A novel pulses discriminator for linear motors direct-drive electrical discharge machining and a control strategy for its high efficiency deep-hole processing with thin electrode are proposed. From the fundamental experiments, both conventional ZNC EDM and the direct-driven (LmEDM for short) reveal machining speed break-away points. Associated with the feedback from a novel effective pulse discriminator, a reasonable EDM jump control is further proposed. It is found the direct–drive EDM with such a control is much more efficient than traditional ZNC-EDM by totally three times of speed, for the aspect ratio of 17.5 of deep EDM. Conducted by LmEDM alone, it can also achieve two times of ZNC-EDM speed. Moreover, the surface integrity is also improved with less wear of electrode and higher wall straightness. It is contributed from more efficient debris processing by the effective pulses information, high acceleration of linear motors, and reasonable jump control.
2012 IEEE/ASME International Conference on Advanced Intelligent Mechatronics (AIM), 2012
ABSTRACT A novel direct-driven electrical discharge machining (EDM) based upon linear motors and ... more ABSTRACT A novel direct-driven electrical discharge machining (EDM) based upon linear motors and a machining feedback by pulses discriminator was proposed. Conventional EDM allowed only fixed setting of jump parameters, which wasted lots of effective working time. An effective pulse discriminator was developed to detect gap status under direct-drive EDM situation. By introducing this pulses discriminator, an adjustable EDM jump control associated with this feedback removal information was proposed. It is evident from experiments that this discriminator is effective and such a jump controller is more efficient than traditional one. For example, its machining speed is risen up to 3.5 times compared to conventional one in aspect ratio of 17.5 deep EDM platelet processing. Its surface integrity and more uniform gap width are also improved significantly, resulted from better debris expelling than conventional EDM flushing processes.
An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-w... more An electrochemical machining (ECM) process for microcavity fabrication with deionized water (DI-water) and an ECM polishing hybrid with alumina powder of 1.0 μm grains on a single micro-EDM machine are proposed. The process adopts tungsten carbide as tool electrode and M-333 tool steel as the mold material. It reveals that employing the 30 μm/min feed rate with 50 mA and 0.2 ms of pulse-width is suitable for DI-water electrochemical machining. The DI-water ECM process can achieve an excellent surface roughness at Ra 0.169 µm on a semispherical round cavity. Combining the ECM with hybrid polishing with the alumina powder can achieve a better profile for a much deeper cavity than pure electrolytic discharge machining. The hybrid ECM polishing can efficiently finish a micro square insert of 0.6 mm length at 64 μm depth. Such ECM milling can achieve an S-shaped microchannel of radius 1.0 mm and a slot of 1.0 × 0.5 mm2 with 110 μm depth, demonstrating its feasibility and the surface inte...
Owing to its low removal rate and debris ejection nature, EDM is a very slow machining process. A... more Owing to its low removal rate and debris ejection nature, EDM is a very slow machining process. A novel jump motion control for electrode in electrical discharge machining (EDM) equipped with dual linear motors (LmEDM) was proposed to release this debris efficiency point. The direct drive EDM and a novel pulse discriminator were developed. By introducing the discriminator to count effective discharge pulses, an EDM jump control was proposed. Experiments for verification of the EDM efficiency were conducted for 35 mm deep and thin EDM processes with 2 mm thin platelet. EDM efficiency of proposed jump control is verified to be four times over the traditional EDM.
ASME 2012 International Manufacturing Science and Engineering Conference, 2012
ABSTRACT Conventional micro EDM milling relies on time-consuming WEDG to achieve acceptable quali... more ABSTRACT Conventional micro EDM milling relies on time-consuming WEDG to achieve acceptable quality of micro tools. In this study, a rotational axis augmented to Wire Electrical Discharge Grinding (WEDG) processes with ultrasonic assistance and its application to EDM micro-milling is reported. On its removing mechanism, a quantitative analysis based upon wire-EDM discharge-angle was proposed to clarify fundamental understanding of such a novel multi-axial machining process. Then, a test on EDM micro-milling with 70 microns of diameter tool is conducted. Its significant effects on improving dressing efficiency and surface integrity of micro tools were verified, and the effectiveness for EDM micro-milling with a screw type of tool was also verified experimentally. Because of its geometric properties, the screw surface contributed to deliver debris from machining region to outsider. Therefore, a better EDM micro-milling configuration may be introduced into the micro-EDM manufacturing field.
A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-hole... more A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 m in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70oC of water to reveal the final product—a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper ...
Journal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers - Series C
A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-hole... more A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 pm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70 degrees C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery withou...
Journal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers - Series C
A novel pulses discriminator for linear motors direct-drive electrical discharge machining and a ... more A novel pulses discriminator for linear motors direct-drive electrical discharge machining and a control strategy for its high efficiency deep-hole processing with thin electrode are proposed. From the fundamental experiments, both conventional ZNC EDM and the direct-driven (LmEDM for short) reveal machining speed break-away points. Associated with the feedback from a novel effective pulse discriminator, a reasonable EDM jump control is further proposed. It is found the direct–drive EDM with such a control is much more efficient than traditional ZNC-EDM by totally three times of speed, for the aspect ratio of 17.5 of deep EDM. Conducted by LmEDM alone, it can also achieve two times of ZNC-EDM speed. Moreover, the surface integrity is also improved with less wear of electrode and higher wall straightness. It is contributed from more efficient debris processing by the effective pulses information, high acceleration of linear motors, and reasonable jump control.
2012 IEEE/ASME International Conference on Advanced Intelligent Mechatronics (AIM), 2012
ABSTRACT A novel direct-driven electrical discharge machining (EDM) based upon linear motors and ... more ABSTRACT A novel direct-driven electrical discharge machining (EDM) based upon linear motors and a machining feedback by pulses discriminator was proposed. Conventional EDM allowed only fixed setting of jump parameters, which wasted lots of effective working time. An effective pulse discriminator was developed to detect gap status under direct-drive EDM situation. By introducing this pulses discriminator, an adjustable EDM jump control associated with this feedback removal information was proposed. It is evident from experiments that this discriminator is effective and such a jump controller is more efficient than traditional one. For example, its machining speed is risen up to 3.5 times compared to conventional one in aspect ratio of 17.5 deep EDM platelet processing. Its surface integrity and more uniform gap width are also improved significantly, resulted from better debris expelling than conventional EDM flushing processes.
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