Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D:Materials and Processing".

Deadline for manuscript submissions: closed (15 September 2020) | Viewed by 43247

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Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council, 70124 Bari, Italy
Interests: micro EDM; micro manufacturing; additive manufacturing; virtual prototyping
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Micro Electrical Discharge Machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Among the various micro-machining processes, micro-EDM is known to have many industrial applications, such as high-aspect-ratio micro holes for fuel injectors, high-precision moulds, and biomedical components. The main issues restricting the application of micro-EDM involve handling and fixturing, electrode and workpiece preparation, process parameter optimization, the identification and minimization of source of errors as tool wear, and measurement issues.

In the recent past, numerous EDM systems have been developed for performing micro- and nano-scale EDM. These systems use newer control strategies and optimization methodologies to perform the EDM processes.

This Special Issue pursues contributions (research papers, short communications, and review articles) that focus on recent developments in micro-EDM machining. Topics of interest include but are not limited to the following:

  • Process mechanism modeling and simulation;
  • Process monitoring and control;
  • Parameters optimization;
  • Tool wear management;
  • Novel machine concept;
  • New material processing;
  • Dielectrics;
  • High-aspect-ratio features and surface texturing;
  • Hybrid machining;
  • New application of micro-EDM process.

We look forward to receiving your submissions.

Dr. Irene Fassi
Dr. Francesco Modica
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Micro EDM
  • Parameters optimization
  • Process simulation
  • Tool wear
  • Difficult-to-cut material

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Published Papers (14 papers)

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Editorial

Jump to: Research, Review

3 pages, 149 KiB  
Editorial
Editorial for the Special Issue on Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications
by Irene Fassi and Francesco Modica
Micromachines 2021, 12(5), 554; https://doi.org/10.3390/mi12050554 - 13 May 2021
Cited by 3 | Viewed by 1486
Abstract
Micro Electrical Discharge Machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed [...] Full article

Research

Jump to: Editorial, Review

12 pages, 3576 KiB  
Article
An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material
by Douyan Zhao, Zhaoyang Zhang, Hao Zhu, Zenghui Cao and Kun Xu
Micromachines 2021, 12(1), 22; https://doi.org/10.3390/mi12010022 - 27 Dec 2020
Cited by 19 | Viewed by 2499
Abstract
Electrochemical discharge machining (ECDM) and laser machining are emerging nontraditional machining technologies suitable for micro-processing of insulating and hard-brittle materials typified by glass. However, poor machinability of glass is a major constraint, which remains to be solved. For the micro-grooves processed by ECDM, [...] Read more.
Electrochemical discharge machining (ECDM) and laser machining are emerging nontraditional machining technologies suitable for micro-processing of insulating and hard-brittle materials typified by glass. However, poor machinability of glass is a major constraint, which remains to be solved. For the micro-grooves processed by ECDM, the bottom surface is usually uneven and associated with protrusion structures, while the edges are not straight with obvious wave-shaped heat-affected zones (HAZs) and over-cutting. Besides, the cross section of the micro-grooves processed by the laser is V-shape with a large taper. To solve these problems, this study proposed the laser-assisted ECDM for glass micro-grooving, which combines ECDM and laser machining. This study compared morphological features of the single processing method and the hybrid processing method. The results show that ECDM caused cylindrical protrusions at the bottom of the microgrooves. After processing these micro-grooves by laser, the cylindrical protrusions were removed. However, the edge quality of the microgrooves was still poor. Therefore, we used the laser to get microgrooves first, so we got micro-grooves with better edge quality. Then we use ECDM to improve the taper of microgrooves and the cross-sectional shape of the microgrooves transformed from a V-shape to a U-shape. Full article
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15 pages, 6327 KiB  
Article
Processing Characteristics of Micro Electrical Discharge Machining for Surface Modification of TiNi Shape Memory Alloys Using a TiC Powder Dielectric
by Ziliang Zhu, Dengji Guo, Jiao Xu, Jianjun Lin, Jianguo Lei, Bin Xu, Xiaoyu Wu and Xujin Wang
Micromachines 2020, 11(11), 1018; https://doi.org/10.3390/mi11111018 - 20 Nov 2020
Cited by 27 | Viewed by 2599
Abstract
Titanium-nickel shape memory alloy (SMA) has good biomedical application value as an implant. Alloy corrosion will promote the release of toxic nickel ions and cause allergies and poisoning of cells and tissues. With this background, surface modification of TiNi SMAs using TiC-powder-assisted micro-electrical [...] Read more.
Titanium-nickel shape memory alloy (SMA) has good biomedical application value as an implant. Alloy corrosion will promote the release of toxic nickel ions and cause allergies and poisoning of cells and tissues. With this background, surface modification of TiNi SMAs using TiC-powder-assisted micro-electrical discharge machining (EDM) was proposed. This aims to explore the effect of the electrical discharge machining (EDM) parameters and TiC powder concentration on the machining properties and surface characteristics of the TiNi SMA. It was found that the material removal rate (MRR), surface roughness, and thickness of the recast layer increased with an increase in the discharge energy. TiC powder’s addition had a positive effect on increasing the electro-discharge frequency and MRR, reducing the surface roughness, and the maximum MRR and the minimum surface roughness occurred at a mixed powder concentration of 5 g/L. Moreover, the recast layer had good adhesion and high hardness due to metallurgical bonding. XRD analysis found that the machined surface contains CuO2, TiO2, and TiC phases, contributing to an increase in the surface microhardness from 258.5 to 438.7 HV, which could be beneficial for wear resistance in biomedical orthodontic applications. Full article
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14 pages, 5033 KiB  
Article
Study on ZrB2-Based Ceramics Reinforced with SiC Fibers or Whiskers Machined by Micro-Electrical Discharge Machining
by Mariangela Quarto, Giuliano Bissacco and Gianluca D’Urso
Micromachines 2020, 11(11), 959; https://doi.org/10.3390/mi11110959 - 26 Oct 2020
Cited by 5 | Viewed by 1511
Abstract
The effects of different reinforcement shapes on stability and repeatability of micro electrical discharge machining were experimentally investigated for ultra-high-temperature ceramics based on zirconium diboride (ZrB2) doped by SiC. Two reinforcement shapes, namely SiC short fibers and SiC whiskers were selected [...] Read more.
The effects of different reinforcement shapes on stability and repeatability of micro electrical discharge machining were experimentally investigated for ultra-high-temperature ceramics based on zirconium diboride (ZrB2) doped by SiC. Two reinforcement shapes, namely SiC short fibers and SiC whiskers were selected in accordance with their potential effects on mechanical properties and oxidation performance. Specific sets of process parameters were defined minimizing the short circuits in order to identify the best combination for different pulse types. The obtained results were then correlated with the energy per single discharge and the discharges occurred for all the combinations of material and pulse type. The pulse characterization was performed by recording pulses data by means of an oscilloscope, while the surface characteristics were defined by a 3D reconstruction. The results indicated how reinforcement shapes affect the energy efficiency of the process and change the surface aspect. Full article
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17 pages, 6859 KiB  
Article
Investigation of a Liquid-Phase Electrode for Micro-Electro-Discharge Machining
by Ruining Huang, Ying Yi, Erlei Zhu and Xiaogang Xiong
Micromachines 2020, 11(10), 935; https://doi.org/10.3390/mi11100935 - 14 Oct 2020
Cited by 3 | Viewed by 2200
Abstract
Micro-electro-discharge machining (μEDM) plays a significant role in miniaturization. Complex electrode manufacturing and a high wear ratio are bottlenecks for μEDM and seriously restrict the manufacturing of microcomponents. To solve the electrode problems in traditional EDM, a µEDM method using liquid metal as [...] Read more.
Micro-electro-discharge machining (μEDM) plays a significant role in miniaturization. Complex electrode manufacturing and a high wear ratio are bottlenecks for μEDM and seriously restrict the manufacturing of microcomponents. To solve the electrode problems in traditional EDM, a µEDM method using liquid metal as the machining electrode was developed. Briefly, a liquid-metal tip was suspended at the end of a capillary nozzle and used as the discharge electrode for sparking the workpiece and removing workpiece material. During discharge, the liquid electrode was continuously supplied to the nozzle to eliminate the effects of liquid consumption on the erosion process. The forming process of a liquid-metal electrode tip and the influence of an applied external pressure and electric field on the electrode shape were theoretically analyzed. The effects of external pressure and electric field on the material removal rate (MRR), liquid-metal consumption rate (LMCR), and groove width were experimentally analyzed. Simulation results showed that the external pressure and electric field had a large influence on the electrode shape. Experimental results showed that the geometry and shape of the liquid-metal electrode could be controlled and constrained; furthermore, liquid consumption could be well compensated, which was very suitable for µEDM. Full article
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16 pages, 4601 KiB  
Article
Pulse-Type Influence on the Micro-EDM Milling Machinability of Si3N4–TiN Workpieces
by Valeria Marrocco, Francesco Modica, Vincenzo Bellantone, Valentina Medri and Irene Fassi
Micromachines 2020, 11(10), 932; https://doi.org/10.3390/mi11100932 - 13 Oct 2020
Cited by 25 | Viewed by 2596
Abstract
In this paper, the effect of the micro-electro discharge machining (EDM) milling machinability of Si3N4–TiN workpieces was investigated. The material removal rate (MRR) and tool wear rate (TWR) were analyzed in relation to discharge pulse types in order to [...] Read more.
In this paper, the effect of the micro-electro discharge machining (EDM) milling machinability of Si3N4–TiN workpieces was investigated. The material removal rate (MRR) and tool wear rate (TWR) were analyzed in relation to discharge pulse types in order to evaluate how the different pulse shapes impact on such micro-EDM performance indicators. Voltage and current pulse waveforms were acquired during micro-EDM trials, scheduled according to a Design of Experiment (DOE); then, a pulse discrimination algorithm was used to post-process the data off-line and discriminate the pulse types as short, arc, delayed, or normal. The analysis showed that, for the considered process parameter combinations, MRR was sensitive only to normal pulses, while the other pulse types had no remarkable effect on it. On the contrary, TWR was affected by normal pulses, but the occurrence of arcs and delayed pulses induced unexpected improvements in tool wear. Those results suggest that micro-EDM manufacturing of Si3N4–TiN workpiece is relevantly different from the micro-EDM process performed on metal workpieces such as steel. Additionally, the inspection of the Si3N4–TiN micro-EDM surface, performed by SEM and EDS analyses, showed the presence of re-solidified droplets and micro-cracks, which modified the chemical composition and the consequent surface quality of the machined micro-features. Full article
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14 pages, 4679 KiB  
Article
Surface Characterization and Tribological Performance Analysis of Electric Discharge Machined Duplex Stainless Steel
by Timur Rizovich Ablyaz, Evgeny Sergeevich Shlykov, Karim Ravilevich Muratov, Amit Mahajan, Gurpreet Singh, Sandeep Devgan and Sarabjeet Singh Sidhu
Micromachines 2020, 11(10), 926; https://doi.org/10.3390/mi11100926 - 07 Oct 2020
Cited by 25 | Viewed by 3188
Abstract
The present article focused on the surface characterization of electric discharge machined duplex stainless steel (DSS-2205) alloy with three variants of electrode material (Graphite, Copper-Tungsten and Tungsten electrodes). Experimentation was executed as per Taguchi L18 orthogonal array to inspect the influence of electric [...] Read more.
The present article focused on the surface characterization of electric discharge machined duplex stainless steel (DSS-2205) alloy with three variants of electrode material (Graphite, Copper-Tungsten and Tungsten electrodes). Experimentation was executed as per Taguchi L18 orthogonal array to inspect the influence of electric discharge machining (EDM) parameters on the material removal rate and surface roughness. The results revealed that the discharge current (contribution: 45.10%), dielectric medium (contribution: 18.24%) majorly affects the material removal rate, whereas electrode material (contribution: 38.72%), pulse-on-time (contribution: 26.11%) were the significant parameters affecting the surface roughness. The machined surface at high spark energy in EDM oil portrayed porosity, oxides formation, and intermetallic compounds. Moreover, a pin-on-disc wear analysis was executed and the machined surface exhibits 70% superior wear resistance compared to the un-machined sample. The surface thus produced also exhibited improved surface wettability responses. The outcomes depict that EDMed DSS alloy can be considered in the different biomedical and industrial applications. Full article
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13 pages, 4080 KiB  
Article
Surface Quality Improvement of 3D Microstructures Fabricated by Micro-EDM with a Composite 3D Microelectrode
by Jianguo Lei, Kai Jiang, Xiaoyu Wu, Hang Zhao and Bin Xu
Micromachines 2020, 11(9), 868; https://doi.org/10.3390/mi11090868 - 19 Sep 2020
Cited by 5 | Viewed by 2188
Abstract
Three-dimensional (3D) microelectrodes used for processing 3D microstructures in micro-electrical discharge machining (micro-EDM) can be readily prepared by laminated object manufacturing (LOM). However, the microelectrode surface always appears with steps due to the theoretical error of LOM, significantly reducing the surface quality of [...] Read more.
Three-dimensional (3D) microelectrodes used for processing 3D microstructures in micro-electrical discharge machining (micro-EDM) can be readily prepared by laminated object manufacturing (LOM). However, the microelectrode surface always appears with steps due to the theoretical error of LOM, significantly reducing the surface quality of 3D microstructures machined by micro-EDM with the microelectrode. To address the problem above, this paper proposes a filling method to fabricate a composite 3D microelectrode and applies it in micro-EDM for processing 3D microstructures without steps. The effect of bonding temperature and Sn film thickness on the steps is investigated in detail. Meanwhile, the distribution of Cu and Sn elements in the matrix and the steps is analyzed by the energy dispersive X-ray spectrometer. Experimental results show that when the Sn layer thickness on the interface is 8 μm, 15 h after heat preservation under 950 °C, the composite 3D microelectrodes without the steps on the surface were successfully fabricated, while Sn and Cu elements were evenly distributed in the microelectrodes. Finally, the composite 3D microelectrodes were applied in micro-EDM. Furthermore, 3D microstructures without steps on the surface were obtained. This study verifies the feasibility of machining 3D microstructures without steps by micro-EDM with a composite 3D microelectrode fabricated via the proposed method. Full article
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16 pages, 2843 KiB  
Article
Enhancing Corrosion and Wear Resistance of Ti6Al4V Alloy Using CNTs Mixed Electro-Discharge Process
by Gurpreet Singh, Timur Rizovich Ablyaz, Evgeny Sergeevich Shlykov, Karim Ravilevich Muratov, Amandeep Singh Bhui and Sarabjeet Singh Sidhu
Micromachines 2020, 11(9), 850; https://doi.org/10.3390/mi11090850 - 12 Sep 2020
Cited by 27 | Viewed by 3206
Abstract
This paper presents wear and corrosion resistance analysis of carbon nanotubes coated with Ti-6Al-4V alloy processed by electro-discharge treatment. The reported work is carried out using Taguchi’s L18 orthogonal array to design the experimental matrix by varying five input process parameters i.e., dielectric [...] Read more.
This paper presents wear and corrosion resistance analysis of carbon nanotubes coated with Ti-6Al-4V alloy processed by electro-discharge treatment. The reported work is carried out using Taguchi’s L18 orthogonal array to design the experimental matrix by varying five input process parameters i.e., dielectric medium (plain dielectric, multi-walled carbon nanotubes (MWCNTs) mixed dielectric), current (1–4 A), pulse-on-time (30–60 µs), pulse-off-time (60–120 µs), and voltage (30–50 V). The output responses are assessed in terms of microhardness and surface roughness of the treated specimen. X-ray diffraction (XRD) spectra of the coated sample reveal the formation of intermetallic compounds, oxides, and carbides, whereas surface morphology is observed using scanning electron microscopy (SEM) analysis. For the purpose of the in-vitro wear behavior of treated samples, the surface with superior microhardness values in plain dielectric and MWCNTs mixed dielectric is compared using a pin-on-disc type wear test. Furthermore, electrochemical corrosion test is also conducted to portray the dominance of treated substrate of Ti-6Al-4V alloy for biomedical applications. It is concluded that the wear-resistant and the corrosion protection efficiency of the MWCNTs treated substrate enhanced to 95%, and 96.63%, respectively. Full article
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14 pages, 24175 KiB  
Article
Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool
by Yung-Yi Wu, Tzu-Wei Huang and Dong-Yea Sheu
Micromachines 2020, 11(7), 675; https://doi.org/10.3390/mi11070675 - 11 Jul 2020
Cited by 14 | Viewed by 6779
Abstract
Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining [...] Read more.
Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15. Full article
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14 pages, 6395 KiB  
Article
Shaping Soft Robotic Microactuators by Wire Electrical Discharge Grinding
by Edoardo Milana, Mattia Bellotti, Benjamin Gorissen, Jun Qian, Michaël De Volder and Dominiek Reynaerts
Micromachines 2020, 11(7), 661; https://doi.org/10.3390/mi11070661 - 04 Jul 2020
Cited by 4 | Viewed by 2895
Abstract
Inflatable soft microactuators typically consist of an elastic material with an internal void that can be inflated to generate a deformation. A crucial feature of these actuators is the shape of ther inflatable void as it determines the bending motion. Due to fabrication [...] Read more.
Inflatable soft microactuators typically consist of an elastic material with an internal void that can be inflated to generate a deformation. A crucial feature of these actuators is the shape of ther inflatable void as it determines the bending motion. Due to fabrication limitations, low complex void geometries are the de facto standard, severely restricting attainable motions. This paper introduces wire electrical discharge grinding (WEDG) for shaping the inflatable void, increasing their complexity. This approach enables the creation of new deformation patterns and functionalities. The WEDG process is used to create various moulds to cast rubber microactuators. These microactuators are fabricated through a bonding-free micromoulding process, which is highly sensitive to the accuracy of the mould. The mould cavity (outside of the actuator) is defined by micromilling, whereas the mould insert (inner cavity of the actuator) is defined by WEDG. The deformation patterns are evaluated with a multi-segment linear bending model. The produced microactuators are also characterised and compared with respect to the morphology of the inner cavity. All microactuators have a cylindrical shape with a length of 8 mm and a diameter of 0.8 mm. Actuation tests at a maximum pressure of 50 kPa indicate that complex deformation patterns such as curling, differential bending or multi-points bending can be achieved. Full article
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14 pages, 5450 KiB  
Article
Applying Foil Queue Microelectrode with Tapered Structure in Micro-EDM to Eliminate the Step Effect on the 3D Microstructure’s Surface
by Bin Xu, Kang Guo, Likuan Zhu, Xiaoyu Wu and Jianguo Lei
Micromachines 2020, 11(3), 335; https://doi.org/10.3390/mi11030335 - 24 Mar 2020
Cited by 5 | Viewed by 2279
Abstract
When using foil queue microelectrodes (FQ-microelectrodes) for micro electrical discharge machining (micro-EDM), the processed results of each foil microelectrode (F-microelectrode) can be stacked to construct three-dimensional (3D) microstructures. However, the surface of the 3D microstructure obtained from this process will have a step [...] Read more.
When using foil queue microelectrodes (FQ-microelectrodes) for micro electrical discharge machining (micro-EDM), the processed results of each foil microelectrode (F-microelectrode) can be stacked to construct three-dimensional (3D) microstructures. However, the surface of the 3D microstructure obtained from this process will have a step effect, which has an adverse effect on the surface quality and shape accuracy of the 3D microstructures. To focus on this problem, this paper proposes to use FQ-microelectrodes with tapered structures for micro-EDM, thereby eliminating the step effect on the 3D microstructure’s surface. By using a low-speed wire EDM machine, a copper foil with thickness of 300 μm was processed to obtain a FQ-microelectrode in which each of the F-microelectrodes has a tapered structure along its thickness direction. These tapered structures could effectively improve the construction precision of the 3D microstructure and effectively eliminate the step effect. In this paper, the effects of the taper angle and the number of microelectrodes on the step effect were investigated. The experimental results show that the step effect on the 3D microstructure’s surface became less evident with the taper angle and the number of F-microelectrodes increased. Finally, under the processing voltage of 120 V, pulse width of 1 μs and pulse interval of 10 μs, a FQ-microelectrode (including 40 F-microelectrodes) with 10° taper angle was used for micro-EDM. The obtained 3D microstructure has good surface quality and the step effect was essentially eliminated. Full article
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11 pages, 3251 KiB  
Article
Electrodischarge Drilling of Microholes in c-BN
by Dominik Wyszynski, Wojciech Bizon and Krzysztof Miernik
Micromachines 2020, 11(2), 179; https://doi.org/10.3390/mi11020179 - 10 Feb 2020
Cited by 9 | Viewed by 2014
Abstract
Cubic boron nitride (c-BN) is a “difficult-to-cut” material. High precision machining of this material is problematic because it is difficult to control the material removal rate and maintain acceptable accuracy. This paper describes an application of electrodischarge machining (EDM) for drilling micro holes [...] Read more.
Cubic boron nitride (c-BN) is a “difficult-to-cut” material. High precision machining of this material is problematic because it is difficult to control the material removal rate and maintain acceptable accuracy. This paper describes an application of electrodischarge machining (EDM) for drilling micro holes in c-BN. The goal of this research was to determine a set of parameters and technical specifications for such a process. We used an isoenergetic transistor power supply with a microsecond voltage pulse generator and a tungsten tool electrode of diameter d = 381 μm. Each hole was drilled for 10 min. The holes did not exceed 410 μm in diameter and were at least 1000 μm deep. The process was carried out in a hydrocarbon dielectric liquid. We assess the quality of the holes from a qualitative and quantitative point of view. The results show that electrodischarge is a precise, accurate, and efficient method for machining c-BN. Full article
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Review

Jump to: Editorial, Research

24 pages, 2014 KiB  
Review
Recent Advances and Perceptive Insights into Powder-Mixed Dielectric Fluid of EDM
by Asarudheen Abdudeen, Jaber E. Abu Qudeiri, Ansar Kareem, Thanveer Ahammed and Aiman Ziout
Micromachines 2020, 11(8), 754; https://doi.org/10.3390/mi11080754 - 31 Jul 2020
Cited by 53 | Viewed by 5423
Abstract
Electrical discharge machining (EDM) is an advanced machining method which removes metal by a series of recurring electrical discharges between an electrode and a conductive workpiece, submerged in a dielectric fluid. Even though EDM techniques are widely used to cut hard materials, low [...] Read more.
Electrical discharge machining (EDM) is an advanced machining method which removes metal by a series of recurring electrical discharges between an electrode and a conductive workpiece, submerged in a dielectric fluid. Even though EDM techniques are widely used to cut hard materials, low efficiency and high tool wear remain remarkable challenges in this process. Various studies, such as mixing different powders to dielectric fluids, are progressing to improve their efficiency. This paper reviews advances in the powder-mixed EDM process. Furthermore, studies about various powders used for the process and its comparison are carried out. This review looks at the objectives of achieving a more efficient metal removal rate, reduction in tool wear, and improved surface quality of the powder-mixed EDM process. Moreover, this paper helps researchers select suitable powders which are exhibiting better results and identifying different aspects of powder-mixed dielectric fluid of EDM. Full article
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