Tool fabrication system for micro/nano milling—function analysis and design of a six-axis Wire EDM machine

Abstract

The dies or molds used for the fabrication of micro products usually are made of ultra-hard materials such as tungsten carbide or silicon carbide and have sophisticated three-dimensional geometries. Such kind of dies or molds can only be fabricated by milling operations instead of grinding processes with ultra-hard milling tools made of PCD or CBN. Electrical discharge machining (EDM) is a good choice for the fabrication of such ultrahard tools. In this paper, a function analysis and design of a six-axis Wire EDM (WEDM) machine is introduced. Based on the typical micro/nano cutting tool geometry features, a mathematical model between the cutting tool and the electrode wire is built. Then, the mathematical model is analyzed and it turns out that six axes are needed for cutting such complicated tool geometries. According to the WEDM features, first the axes are allocated to the workpiece side and the electrode wire side. The workpiece is assigned three linear motions and one rotary motion around its center line and the wire has two rotary motions. Second, the axis sequences are defined. At last, the best concept of the mechanical structure for the six-axis WEDM machine is selected.

Study on the generative design method and error budget of a novel desktop multi-axis laser machine for micro tool fabrications

“…2, where ∑O has the X-axis pointing from O to O 1 , Y-axis pointing from O to A, and Z-axis is at the center line of the rotational axis of the ball end mill. ∑P has the X-axis pointing from P to P 1 , Y-axis pointing from O to P, and Z-axis is tangent to arc ABC at point P. Based on the generative design method as discussed in [13], line PP 1 is selected as the generating line, and arc ABC is selected as the guide line. Point P 1 represents the arbitrary point on the ball end mill geometry to be machined and overlaps P while L equals 0.…”

“…A generative design method was introduced in [12] and used for a lathe design, which gave reasonable and intuitionistic answers to machine tool designs. By this method, a six-axis WEDM machine has been functionally analyzed and developed [13,14].…”

Novel Tool Design Method for Orbiting EDM -A 2nd Approach on Design Automation Developed in CAD-

“…This technique allows treating tool steel to its full hardness prior EDM, hence avoid the problems of geometry distortion caused by material post treatment (1) . Recently, EDM becomes a common manufacturing method to fabricate parts especially in aerospace and automobile where production quantities are relatively low (2) , mould and die industries, and small and burr-free hole drilling (3) . This process also provides an efficient way to produce delicate parts which might not be feasible by traditional machining.…”

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

“…The Wire EDM applies precise cutting action to make intricate shapes and patterns. Diamond end mills with high accuracy and edge sharpness are machined using the Wire EDM method [8,12]. A study on WEDM process optimization for PCD micro milling tool has been carried out [9].…”

“…Although it has been shown that these three methods are versatile for machining difficult-to-work materials, low machining efficiency is one of their main disadvantages. How to increase eroding speed, reduce the wear of electrode and maintain reasonable accuracy at the same time has always been the topic of EDM [11][12][13][14][15][16]. As for fabricating PCD tools, the aforementioned studies mainly focus on the methods of using the Sinker EDM and the Wire EDM [12,14,[17][18][19][20][21][22][23][24][25].…”