Fabrication of a micro-spherical tool in EDM combined with Ni-diamond co-deposition

Hung, Jung Chou; Lien, Shao Chun; Lin, Jui Kuan; Huang, Fuang Yuan; Yan, Biing Hwa

doi:10.1088/0960-1317/18/4/045010

Cited by 9 publications

(7 citation statements)

References 10 publications

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“…The objective was to use those fabricated tools for grinding of ZrO2 ceramics. A similar study by Jung et al reported same technique of combined EDM and co-deposition to fabricate the spherical tool for grinding nickel alloy mould [28]. In addition, several researchers have used micro-EDM and micro-grinding hybrid process for fabricating simple-shaped grinding tool for machining different materials.…”

Section: Introductionmentioning

confidence: 96%

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Perveen

San

Rahman

2011

Int J Adv Manuf Technol

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With the demand for microstructures of not only with diversified shape but also of reduced dimension on glass, fabrication of polycrystalline diamond (PCD) tool/ microelectrodes with different shape has become important. However, to date, fabrication of different shapes in single setup is not possible and also needs special indexing attachment. To solve this problem, in this study, a specially designed block containing three v-slots of 60°, 90°, and 120°has been designed and fabricated using wire cut. Thereafter with the help of block electro-discharge machining method and using this specially designed block, different shapes of microelectrodes with symmetrical and non-symmetrical section has been fabricated. This study also investigates the feasibility of using these different geometry PCD tool for micro-grinding of BK7 glass. In this context, a relative study on the micro-grinding performance of four different geometry tools (circular, D-shaped, triangular, and square) has been carried out. It has been observed that among the different shaped tools, D-shaped tool experienced lowest cutting force along x-and y-axes where as triangular tool faced lowest force along z-axis, and highest cutting forces were found to be experienced by square tool. Average and maximum roughness of machined surface was found to be improved from circular to others tool except triangular one. But, it was also observed that side surface started to deteriorate from circular to other tool due to edge wear. In case of tool wear, square and triangular tool experienced more wear than circular and D-shaped tool due to their frequent edge blunting or rounding effect. Finally, among four different geometry tools, D-shaped tool was considered to provide better performance in terms of the achieved surface finish, tool wear, and cutting force analysis.

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Section: Introductionmentioning

confidence: 96%

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Perveen

San

Rahman

2011

Int J Adv Manuf Technol

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“…The machining force in EDM is extremely small; thus, the problems of tool bending, breaking, and strength decrease due to subsurface damages can be solved effectively. Recently, EDM fabrication of micro tools has been a new topic of research in the area of micro machining [8][9][10][11]. For example, Masaki et al used EDM to machine poly-crystal diamond to fabricate spherical micro tools [8].…”

Section: Introductionmentioning

confidence: 99%

Fabrication of micro end mills by wire EDM and some micro cutting tests

Yan

Uchida

Yoshihara

et al. 2009

J. Micromech. Microeng.

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Extremely fine end mills with noncircular cross-sectional profiles have been fabricated utilizing wire electro discharge machining. By using suitable electro discharging conditions, the geometrical error of the end mill and the roundness of the cutting edge were both controlled below 1 μm. Micro grooving tests were performed on electroless nickel plating using these end mills, and the machining behavior was investigated. Nearly burr-free precision machining was realized. Until a total cutting distance of 1000 mm, no remarkable change was found in the cutting force and chip formation, demonstrating the high anti-wear ability of the tools. It can be presumed that the electro discharge-induced micro asperities on the tool surface play an important role in machining by improving the tribological properties of the tool-workpiece interface.

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“…In some experimental work micro tool is fabricated by (WEDG) combined with ultrasonic vibration by helical micro tool electrode to drill and finish micro holes [35,36]. In one of the experiment micro spherical diamond tool is built by EDM and used to make micro spherical cavity in a high nickel alloy [37]. A micro tool of diameter 100µm was fabricated by (WEDG) over which SiC particles are coated by electrophoretic deposition (EPD) and used to polish microholes in quartz with the help of ultrasonic vibration machining (USM) [38].Using Tungsten carbide cylindrical rod of diameter 300µm as tool electrode micro EDM milling was done directly to get desired slots on stainless steel AISI420 avoiding the need to fabricate complex tools separately [39].…”

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confidence: 99%

Micro-Electro Discharge Machining of Holes and Grooves: AnAssessment of Process Parameters

Bal¹,

Mishra²,

Satapathy³

2017

IJET

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Abstract-The need for a better cooling purpose in bio medical, electronics, microprocessors and radars has attracted many researchers. Since, microchannels fulfil this objective it's machining through different micro machining techniques requires more skill and knowledge. Micro electrical discharge machining (EDM)is considered as one of the advanced methods of machining micro tools, dies, channels, grooves etc. More emphasis should be given to this machining process so that complicated geometries with least effort can be produced. In the present work critical study has been done on different tool materials as well as workpiece materials used on machining work table in micro EDM with different new strategies of machining will be helpful to enhance understanding of the subject. Along with this a direct method of getting tools for making micro holes and grooves on workpiece is suggested.

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Fabrication of a micro-spherical tool in EDM combined with Ni-diamond co-deposition

Cited by 9 publications

References 10 publications

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Fabrication of micro end mills by wire EDM and some micro cutting tests

Micro-Electro Discharge Machining of Holes and Grooves: AnAssessment of Process Parameters

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