Using ultra thin electrodes to produce micro-parts with wire-EDM

Klocke, Fritz; Lung, Dieter; Thomaidis, Dimitrios; Antonoglou, G.

doi:10.1016/j.jmatprotec.2003.10.061

Cited by 38 publications

(8 citation statements)

References 2 publications

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“…A commercial wire-EDM machine developed by a local machine tool builder in Taiwan was retrofitted with a fine wire transport system, a two-axis linear motor stage with sub-micrometre resolution of feed drive, a transistor-controlled power supply and an open architecture CNC system to achieve micromachining purpose and excellent machining results [8]. Tungsten wire with a diameter of 0.05 mm was used as the wire electrode.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…Kim and Hur [7] investigated the influence of machining conditions like discharge frequency and pulse width on the metal removal rate of WEDM of PCD blank. Klocke et al [8] presented the cutting performance of micro wire-EDM when hard tool materials such as polystraline diamond and cemented carbide were used as work piece materials. Single discharge craters and discharge forces were also investigated under various machining conditions.…”

Section: Introductionmentioning

confidence: 99%

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A Study on Pulse Generator for Micro WEDM of Polycrystalline Diamond

Yan

Liu

Fang

2012

KEM

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This paper presents a new pulse generator for cutting of polycrystalline diamond (PCD) by micro wire-EDM. Three pulse control methods (AC power supply pulse control method, fixed pulse width modulation pulse control method and improved AC power supply pulse control method) have been proposed to achieve high frequency and low energy discharge pulses. The improved AC power supply pulse control method enables the pulse generator to provide a period of 20 μs off duty cycle followed by a period of duty cycle for reionization of the dielectric in the spark. Compared to the other two methods, the improved AC method can provide smaller peak current and discharge duration and thereby achieve a smaller slit width and better surface finish. Tests revealed that the developed power supply using anti-electrolysis circuitry and a digital signal processor-based pulse control circuit can provide very low discharge energy pulses with a frequency of 200 KHz, discharge duration of 0.75 μs and a peak current of 3 A. Experimental results demonstrate that the proposed pulse generator can achieve a feed rate of 0.4 mm/min, a surface finish of 0.53 μm Ra and a damaged layer of 5 μm on PCD surface through proper machining settings.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Study on Pulse Generator for Micro WEDM of Polycrystalline Diamond

Yan

Liu

Fang

2012

KEM

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“…A study on WEDM process optimization for PCD micro milling tool has been carried out [9]. However, the thin wires cannot tolerate large discharge energies and would consequently break [10]. Disk erosion, providing larger discharge areas than wire erosion, has its unique advantages.…”

Section: Introductionmentioning

confidence: 99%

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

Zhang

et al. 2015

Int J Adv Manuf Technol

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Polycrystalline diamond (PCD) tools fulfil a vital role in the woodworking industry, with its ability to achieve smooth machining quality and long service life, along with excellent performance features. However, diamond tools' fabrication is a difficult material removal process. In this study, we propose and develop an electrical discharge machining (EDM) grinding method with disk electrode. Tool profiles are captured by a measuring probe, and path curves are tracked by a peripheral disk in edge fabrication. Experiments of graphite and copper serving as electrode are carried out, respectively, in the disk discharge grinding process. In addition, with design of experiments on PCD machining, different Disk EDM parameters are obtained to evaluate the influence of dominant factors on machining speed and surface quality. Optimal gap reference voltage, wheel rotational speed and pulse width are extracted, respectively, under the conditions of two electrode materials. Results show that pulse width plays the most important role in machining, and copper electrode can effectively produce smoother surface than graphite when used as electrode in Disk EDM. Moreover, edge fabrication of spiral miller (φ125 mm) is precisely realized with circular run-out errors less than 0.050 mm.

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“…For example, a 5-kg spool of 0.1 mm diameter wire is just over 20 km long and it can cut for about 60 h, which makes the batch production possible. An appropriate manufacturing process to cover the growing need for accurate small tools is EDM with thin wires [9]. WEDM has been gaining wide acceptance in the machining of the various materials used in modern tooling applications [10].…”

Section: Introductionmentioning

confidence: 99%

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

Cheng

Wang

Kobayashi

et al. 2009

Int J Adv Manuf Technol

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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.

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Using ultra thin electrodes to produce micro-parts with wire-EDM

Cited by 38 publications

References 2 publications

A Study on Pulse Generator for Micro WEDM of Polycrystalline Diamond

A Study on Pulse Generator for Micro WEDM of Polycrystalline Diamond

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

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

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