Development of a computer assistant programming system for micro/nano milling tool fabrication by multi-axis wire EDM

Cheng, Xiang; Wang, Zhigang; Kobayashi, Shigeru; Nakamoto, Kazuo; Yamazaki, Kazuo

doi:10.1080/09511920902866096

Cited by 12 publications

(5 citation statements)

References 11 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Unique WEDM processes need to be considered for tool accuracy and tool fabrication efficiency purposes. Therefore, dedicated CAM system for custom micro tooling is necessary other than traditional CAM systems [10]. Such CAM system has the functions of parametric design, WEDM process planning, wire location generation, and simultaneous multi-axis CNC program creating for custom micro tools.…”

Section: Fabrication Techniques For Custom Micro Toolingmentioning

confidence: 99%

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

Cheng

Zhang

Liu

et al. 2012

AMR

Self Cite

View full text Add to dashboard Cite

Hard and brittle materials such as WC, SiC, and single crystal silicon or germanium are widely used in die/moulds for very high accuracy glass products, medical devices, and sensors for MEMS. Mechanical ductile-mode micro/nano milling is an effective method to create three dimensional geometries on these materials. One of the key factors affecting successfully ductile-mode machining is micro tooling. Due to limitations of commercially available micro tools, custom micro tooling is brought forward to give an active solution to this issue. This paper is a further study on custom micro tooling by the author, and several aspects associated with custom micro tooling have been discussed. Experimental results show the feasibility and effectiveness of the successful ductile-mode machining of hard and brittle materials by custom micro tooling. At last, this paper summarizes the techniques associated with custom micro tooling and point out the key aspects for further research on custom micro tooling.

show abstract

Section: Fabrication Techniques For Custom Micro Toolingmentioning

confidence: 99%

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

Cheng

Zhang

Liu

et al. 2012

AMR

Self Cite

View full text Add to dashboard Cite

show abstract

“…Based on the dedicated computer assistant programming system developed by the authors [26], three newly designed ball end mills (given the names B1, B2 and B3) with the radius of 0.1 mm and rake angle of −60 • have been fabricated. The geometry of the fabricated ball end mill is shown in figure 12.…”

Section: Pcd Ball End Mill Fabricationmentioning

confidence: 99%

Design and development of a micro polycrystalline diamond ball end mill for micro/nano freeform machining of hard and brittle materials

Cheng

Wang

Nakamoto

et al. 2009

J. Micromech. Microeng.

View full text Add to dashboard Cite

Micro end mills play a key role in micro/nano milling applications for intricate three-dimensional die/molds or sensors for micro-electro-mechanical systems (MEMS). In order to achieve higher machining accuracy and longer tool life, micro end mills are usually made of ultra-hard materials such as polycrystalline diamond (PCD) or cubic boron nitride (CBN). One of the best choices for their fabrication is the wire electrical discharge machining (WEDM) method. There are two basic categories of micro end mills, namely the ball end mill for 3D freeform surface machining and straight/round edge end mills for non-freeform surface machining. This paper focuses on the design and development of the micro ball end mill for hard and brittle materials. Firstly, the available typical ball end mill is analyzed. Secondly, a micro ball end mill with uniform axial rake and clearance angles is designed and analyzed by the finite element method (FEM). The designed micro ball end mill only needs simultaneously three linear and one index rotational WEDM axes instead of simultaneously five WEDM axes for traditional ball end mills. Then, micro PCD ball end mills are fabricated and the radius variation follows in ±2.0 μm, which is more accurate than commercially available ones. Finally, the 3D freeform geometry milling on tungsten carbide (WC) and silicon wafer successfully demonstrated the possibility of micro-mechanical freeform machining by the developed micro ball end mill.

show abstract

“…Yan et al [4] utilized the Plucker coordinate representation to describe the free-form ruled surfaces of WEDM components and to generate the corresponding tool path. Cheng et al [5] have developed the method to generate the numerical control (NC) programs automatically for the multi-axis WEDM machine, which can fabricate micro/nano milling tools. Later, Cheng et al [6] have moreover introduced a function analysis and design of a sixaxis WEDM machine.…”

Section: Introductionmentioning

confidence: 99%

Modelling tool path in wire electric discharge machining using Denavit–Hartenberg notation

Hsieh

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

This paper presents a systematic methodology for producing the numerical control (NC) data required to fabricate complex three-dimensional (3D) ruled surfaces using five-axis computer numerical control (CNC) wire electrical discharge machining (WEDM). The proposed approach commences by using the Denavit–Hartenberg (D–H) notation to establish the ability matrix of the WEDM machine. The Plucker coordinate representation is then applied to design the desired ruled surface in terms of a set of control lines. In addition, an offset ruled surface is derived in accordance with the principles of differential geometry in order to account for the wire radius and spark gap. Finally, the required NC data equations are obtained by equating the corresponding elements of the ability matrix and the configuration matrices of the upper and lower wire guide heads respectively. The validity of the proposed methodology is confirmed by machining a workpiece with a cubic Bezier ruled surface on a commercial five-axis CNC WEDM machine.

show abstract

Development of a computer assistant programming system for micro/nano milling tool fabrication by multi-axis wire EDM

Cited by 12 publications

References 11 publications

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

Design and development of a micro polycrystalline diamond ball end mill for micro/nano freeform machining of hard and brittle materials

Modelling tool path in wire electric discharge machining using Denavit–Hartenberg notation

Contact Info

Product

Resources

About