Process performance of micro-EDM drilling of stainless steel

D’Urso, Gianluca Danilo; Maccarini, Giancarlo; Ravasio, Chiara

doi:10.1007/s00170-014-5739-1

Cited by 75 publications

(27 citation statements)

References 16 publications

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“…Since the ejectment of debris particles becomes more difficult as the machining depth increases, the tool wear rate increases independent of voltage and workpiece [13]. When the electrode is penetrated into a workpiece, the sparking conditions alter due to the distribution of electric field strength changes, discharging takes place not only at the bottom, but also at the corner and lateral face [14].…”

Section: Introductionmentioning

confidence: 99%

Effect of Electrode Size on the Performances of Micro-EDM

Liu

Zhang

Zhu

et al. 2015

Materials and Manufacturing Processes

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Understanding the effect of processing parameters on the tool electrode wear during micro electrical discharge machining (Micro EDM) is helpful to predict and compensate the electrode wear, so as to improve the machining precision. In this paper, experiments are carried out and the influences of tool electrode diameter on the micro EDM process are discussed based on the skin effect and area effect. It is demonstrated that the machining speed, tool wear and taper rate are different with the increase of tool electrode diameter. Due to the skin effect and area effect, larger electrode diameter results in higher material removal rate along with higher tool wear rate. The electrode material removal increment is more than the workpiece material removal increment with the increase of tool electrode diameter, which leads to the increase of relative tool wear ratio. Discharge energy is concentrated on the tool surface which enhances the possibility of discharge on the side face and the corner of the tool electrode during the micro EDM, especially when drilling with a larger tool electrode. As a result, a tool electrode with larger diameter results in a higher taper rate.

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Section: Introductionmentioning

confidence: 99%

Effect of Electrode Size on the Performances of Micro-EDM

Liu

Zhang

Zhu

et al. 2015

Materials and Manufacturing Processes

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“…Such electrode tools are usually made of graphite, brass, copper and tungsten alloys. In comparison with other methods EDM drilling is characterized by such advantages as possibility to obtain accurate, burr free and high aspect ratio holes with thin walls and application to machine the wide range of materials, irrespective of their hardness and toughness (harder than a tool materials can be machined) [14][15][16]. However, it is worth to underline that this method has limited application for materials with a high electrical resistivity (a maximum electrical resistivity of 100 Ωcm), during machining significant tool wear and low material removal rate occurs and surface layer has poor integrity and heat affected zone.…”

Section: Electro Discharge Microdrillingmentioning

confidence: 99%

The Capabilities of Electrodischarge Microdrilling of High Aspect Ratio Holes in Ceramic Materials

Skoczypiec

Machno

Bizon

2015

Management and Production Engineering Review

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Accepted: 15 July 2015 In the first part of the article the review of ceramic materials drilling possibilities was presented. Among the described methods special attention is paid to electrodischarge drilling. This process have especially been predicted for machining difficult-to-cut electrically conductive materials. The second part consist of the results analysis of electrodischarge microdrilling of siliconized silicon carbide. The experiment involves the impact of current amplitude, discharge voltage and pulse time on the hole depth, side gap, linear tool wear and mean drilling speed. The results shows that electrodischarge drilling is a good alternative when machining inhomogeneous ceramic materials and gives possibility to drill high aspect ratio holes with relatively high efficiency (the drilling speed >2 mm/min).

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“…Micro-holes are widely used in several applications such as fuel injection system of gasoline engine, nozzle plate of a printer head etc. [4][5][6] whereas micro pins are broadly used in micro heat exchangers [7]. In RµEDM, an arrayed micro-hole on a metallic plate, works as a tool (cathode) and a large-sized work-piece (anode) is aligned over the pre-drilled holes and is fed against these at controlled feed.…”

Section: Introductionmentioning

confidence: 99%

A New Approach of Tool Wear Monitoring and Compensation in RµEDM Process

Nirala

Saha

2015

Materials and Manufacturing Processes

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This paper presents a new approach of tool wear compensation, based on 'volume removal per discharge' ( VRD ) in 'reverse-micro-electrical-discharge machining'. In this process, a plate with pre-drilled micro-hole is used as a tool, the erosion of which limits the fabrication of desired height of micro-rod(s). Therefore, in order to achieve the dimensional accuracy of this micro-rod(s), such tool plate wear needs to be compensated.Since this approach is based on the real-time estimation of volume removal from workpiece, which is obtained by multiplying the number of 'contributing' pulses with the VRD, therefore, an accurate estimation of VRD is very much essential for availing correct tool wear compensation. In this work, VRD is estimated by considering two new aspects; the number of actual 'contributing' pulses and the variation of VRD with machining depth. These pulses are identified by a 'pulse discriminating' system developed in house. The real-time material removal volume from workpiece is then used to estimate the 'real-time height' of micro-rods after considering the over cut and taperness of each micro-rod. The proposed method is also compared with the normal machining method and 'uniform wear method' and found to be more accurate with a negligible error of maximum 1.7%.

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Process performance of micro-EDM drilling of stainless steel

Cited by 75 publications

References 16 publications

Effect of Electrode Size on the Performances of Micro-EDM

Effect of Electrode Size on the Performances of Micro-EDM

The Capabilities of Electrodischarge Microdrilling of High Aspect Ratio Holes in Ceramic Materials

A New Approach of Tool Wear Monitoring and Compensation in RµEDM Process

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