Electrical Discharge Machining

Fundamentals of EDM
The process dates back to WW I & II when work as well as substantial tool material was removed due to manual feeding of electrode. Later vibratory electrodes were used to control inter electrode gap. Two Russian scientists developed R-C circuit and servo controller. The Die sinking version of EDM was developed sometime in 1940s. The process modeling involves understanding of complex hydrodynamic and thermodynamic behavior of the fluid.

Fundamentals of EDM
Preparation Phase

Phase of Discharge

Interval Phase

Fundamentals of EDM
Voltage Current curves (Free, Normal, Stationary located, and Short circuit discharges) General observations Difficult to start the process with very clean dielectric Firing of high current discharges at same voltage is easy in contaminated dielectric New ignition opt to ignite in prior discharge regions Greater ignition preferences in more contaminated regions

Fundamentals of EDM
DC pulses of appropriate shape, frequency and duty cycle are used. This is used even for motor control now-a-days. Frequency is ~ 100,000 Hz. Spark is initiated at the peak between the contacting surfaces and exists only momentarily. Spark temp is 12,000 C. Metal as well as dielectric will evaporate at this intense localized heat. A crater is caused by both due to the local evaporation as well as the vapor action. Vapor quenches and next spark it at another narrow place. Thus, spark wanders throughout the surface making uniform metal removal for the desired finish.

Fundamentals of EDM
Material removal in EDM is based on erosion effect. Several theories have been proposed:
Electro-mechanical theory: electric field force exceeds the cohesive force of lattice. Thermo-mechanical theory: Melting of material by flame-jets. Thermo-electric theory: Generation of extremely high temperature due to high intensity discharge current.

Fundamentals of EDM

Debris and Bubble particles generated by single spark Debris gathering at Bubble boundary

Fundamentals of EDM
Large number of Spherical particles with few nonspherical particles Spherical particles are rich in workpiece material and non-spherical particles are rich in tool material Understanding of Erosion Mechanism and Oxide free power production Important parameters affecting Debris morphology are
Current

Voltage Pulse On-time Capacitance

Input Energy

Fundamentals of EDM
Micro analysis reveals that there is movement of material from workpiece to cathode and vice-versa Normal distribution of particle size (Stochastic nature) Structures of Debris Large Size & Small Size Hollow & Solid Debris Satellite structure Hollow Spheres Dents Burnt Cores

Fundamentals of EDM
Microanalysis of Debris Low Energy
Densely populated, Small diameter, solid particles

a)Dendrite structure; b)Solid sphere; c)Satellite formation; d) Non-spherical particles

Fundamentals of EDM
Larger population of hollow satellites with dents, surface cracks, and burnt core

a)Debris structure, b)Hollow sphere, c)Dendrite structure, d)Satellite with dent formation, e)Dent formation

Fundamentals of EDM
Effect of Tool Rotation.
Results in fine debris particles and improved process stability.

Effect of Ultrasonic Vibrations.

Larger particles Large number of particles with spherical geometry More uniformity of spherical and non-spherical particles Uniform mixing of materials More collision between debris particles

Fundamentals of EDM

Fundamentals of EDM
A series of voltage pulses of magnitude about 20 to 120 V and frequency on the order of 5 kHz is applied between the two electrodes, which are separated by a small gap, typically 0.01 to 0.5 mm. When using RC generators, the voltage pulses are responsible for material removal.

Breakdown of dielectric during one cycle

Temperatures of about 8000 to 12,000 C and heat fluxes up to 1017 W/m2 are attained during process

Breakdown of dielectric during one cycle

Explosion and implosion action of dielectric

EDM performance measures such as material removal rate, electrode tool wear, and surface finish, for the same energy, depends on the shape of the current pulses.

Voltage and Current characteristics

Types of pulses Effect of pulses Pulse classification systems Data acquisition and classification

EDM Schematics

Components of EDM

Tool Wear and Tool Materials

Graphite is suitable material with good electrical conductivity and machinability Copper WCu and WAg Brass

Corner wear ratio

Flushing

The main functions of the dielectric fluid are to 1. Flush the eroded particles from the machining gap 2. Provide insulation between the electrode and the workpiece 3. Cool the section that was heated by the discharging effect The main requirements of the EDM dielectric fluids are adequate viscosity, high flash point, good oxidation stability, minimum odor, low cost, and good electrical discharge efficiency

Parameters affecting EDM performance

Erosion Rate and Surface Finish

Effect of Pulse Current and Pulse on time

EDM hazards

Process Stability
Indication of constantly moving spark

Importance of Debris content in inter-electrode gap Discharge conduction through debris chain Effect on surface cracks Process stability primarily depends on discharge transitivity rather than breakdown strength Absence of Debris can be one of the causes of arching

Processing and Response parameters

Electrode material Accuracy and finish of electrode manufacture Current/ voltage Frequency Pulse width

Operating parameters
Current and voltage: As the voltage drops from A to B, the current increases because of the negative voltage-current relationship. At C, current is interrupted, and voltage goes to zero and reverses to D; but since there is no break down in opposite direction, no current reversal takes place. The voltage now returns to zero and waits for the next pulse.

Operating parameters
The energy dissipated in the system is voltage times current times time, it remains fairly constant. At A energy is zero. B represents the power going to the work. C, D, E and F represent traces at where there are either voltage or current is zero, hence no power. In section B voltage times current is nearly constant, indicates a constant input of power during a current pulse.

Operating parameters
In the inter electrode gap, there is a mixture of electrons, ions, and neutral atoms in the gaseous form. Cathode supplies electrons for the flow of current so should be enough to emit the electrons, also positive ions in front of cathode provide a pulling force. Cathode material also matters Cu is a low melting point alloy so it melts (at 1083 C) and emits electrons by heat and electric field. Graphite, W, Mo emit electrons at the temperatures below there melting points hence are more stable as cathode.

Operating parameters
Resistance to the flow of current is higher near the electrodes. The voltage drop near cathode is smaller as compared to that of anode. It helps electrons in achieving high speed to ionize the gases near cathode. Cathode voltage drop ranges from 12V for Cu to 25V for graphite. The plasma generated is at 6000 to 10,0000 C. (+) ions and electrons (-), due to the mass difference ions move slowly therefore, 95% of the current is carried by electrons. The electrons and ions provide major power input to the cathode and anode surfaces. When the current is high, evaporation of material from anode occurs, the stream of atoms coming out of anode surface interferes with the electrons going to the anode. Some ions get ionized at the near anode drop but the electrons get additional energy to cause more vaporization of anode.

Operating parameters
Straight polarity: in which electrode is usually a cathode (-). Here, work surface energy can be controlled by controlling the current so that anode drop energy provides proper wear and desired surface finish. Reverse polarity: in which electrode anode (+) and work (-), in which rough cut higher cutting rates can be obtained with virtually no electrode wear.

Operating parameters
Electrode rotating: Improves flushing difficulties with speed of about 200 rpm max. It provides better surface finish. Electrode orbiting: Electrode does not rotate but revolve in an orbit. Orbiting need not be restricted to round shape. Both actions reduce electrode wear as it gets distributed uniformly.

Operating parameters
No Wear EDM: It is defined as the condition when the electrode to work wear ratio is 1% or less. Effect of arc duration: Melting depth is a function of arc duration for a circular non expanding heat source. The maximum melting depth occurs at different durations for different materials subjected to same energy. The melting depth reaches a peak value with an increase in arc duration, it reduces with further increase in the arc duration. Thus, it should be possible to choose an arc duration which maximizes the work erosion while holding the electrode to some lesser value. In Cu and steel system, at the arc duration suitable for maximum melting of steel, the melting of Cu is at the minimum.

Operating parameters
Electrode polarity: The energy distribution between anode and cathode is a function of
ratio of electron current to ion current at cathode Physical constant (work function) of the cathode material. In Cu as cathode current density decreases, the electron to ion current ratio also decreases. As the arc duration increases, the energy delivered to the gap concentrates at the cathode. Therefore, the electrode must be of positive duration if long arc durations are used to achieve the no-wear condition.

Electrode coating is observed in Cu-steel system.

Coating of electrodes with thin black film of carbon which has erosion resistance and tend to reduce electrode wear.

Processing and Response parameters

Effect of Current

As current increases, the depth and width of the crater becomes larger. So also the MRR. But this may result in rough surface. However, this can be used to our advantages to obtain matty surface.

Processing and Response parameters

Effect of Frequency

As frequency increases, the depth and width of the crater becomes smaller although the MRR may not be affected as there will be more craters per unit time. However, frequency has a limit since initiation of spark requires certain minimum time required for the breakdown of the dielectric. Similarly the spark needs some time to quench. In principle, one should operate as high a freq as possible.

Processing and Response parameters

Effect of Voltage

Gap Voltage Current Current Gap

Voltage Current MRR Accuracy & finish Poor flow of dielectric.

Processing and Response parameters

Effect on fatigue Life
A layer of resolidified metal of 0.002 0.050 mm thick remains on the surface. This may flake off during cyclic loading. When high fatigue life is required, this layer must be removed on a subsequent operation such as chemical etching.

Machine Construction

EDM process Variations

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Content Percentage

40 30 20 10 0 1 Group Number 2 3 Normal Discharge Open Circuit Abnormal Discharge

Group Number Planetary Motion Debris Layer Input Voltage

Group 1 Group 2 Group 3 Yes Yes 15mV No Yes 15mV No No 15mV

EDM process Variations

Modern controllers uses gap controlling strategy to control debris Dielectric flushing (injection, suction, & electrode jump) Jet sweeping Rotary Electrode/workpiece method.

Without Rotation

With Rotation

EDM process Variations

Magnetic Assistance

Use of Magnetic field

1(05A,20s), 2( 20A,350s)

Magnetic force used to change path of debris motion. Magnets attached on plates rotating under machining zone Magnetic force is useful not only at low energy but also at high energy inputs

EDM process Variations

Vibration Assistance

Condition of Adhesion

Debris removal and Sparking

The combined process of EDM with USM had the potential to prevent debris accumulation, improve machining efficiency, and modify the machined surface.

Dielectric Fluid Desirable properties

Break down characteristic: Non-conducting until breakdown and very high conduction through rapid ionization just after breakdown. High latent heat to minimize evaporation to contain the spark in a narrow region for localized sparking Low viscosity for ease of flow Efficiency as coolant. It is kerosene or water.

Dielectric Fluid
Functions of Dielectric Fluid
It acts as an insulator until sufficiently high potential is reached . Acts as a coolant medium and reduces the extremely high temp. in the arc gap. More importantly, the dielectric fluid is pumped through the arc gap to flush away the eroded particles between the work piece and the electrode which is critical to high metal removal rates and good machining conditions.

Dielectric Fluid
Work Material Fluid Medium Aluminum Brass Mild Steel Stainless steel Tool steel Tungsten Carbide Application

Hydrocarbon oil or glycerin-water (90:10)

Submerged

Mineral oil

Dielectric Fluid
Dielectric fluids: should have very high flash point and very low viscosity.
Petroleum based hydrocarbons Silicon fluids mixture with petroleum oils for machining of titanium, high MRR and good SF. Kerosene, water-in oil emulsion, distilled water.

Cooling of dielectric is required sometimes while cutting with high amperage can be done by using heat exchangers. Filtering of dielectric is necessary to filter out 2 5 m particles.

Dielectric Fluid
Insulation and conduction: Insulating characteristic is measured by the maximum voltage that can be applied before ionization. Cooling: ability to resolidify vaporized material into chips , thermal transfer capability. Flushing: Sufficiently viscous to pass through a small gap &remove debris. Methods of fluid application
Normal flow Reverse flow Jet flushing Immersion flushing

Workpiece and Tool Material

Electrode Materials Applications Brass Copper Zinc Alloys Copper-Graphite Steel Copper Tungsten Graphite High Accuracy for most metals Smooth finish Low accuracy for holes Commonly used for steel, forging cavities General Purpose work Used for nonferrous metals High accuracy for detail work Large volume/fine details Low wear Excellent machinability

Workpiece and Tool Material

Tool electrodes transport current to the work surface. Graphite
Coarse (for large volume) or fine (for fine finish). Normally used for steel provides large MRR/A as compared to other metallic electrodes. When used for WC, deposits of carbon on work leads to flow of current without ionization of dielectric and hence arcing. High density, fine particles preferred. Average surface finish using graphite electrodes:0.5 m Ra.

Copper Graphite
For rough and finish machining of WC.

Workpiece and Tool Material

Copper
When smoothest surface finish is required. In no-wear mode, copper works best under low ampere and long spark times. Tellurium increases the machinability of copper. Free machining brass is used for making complex shaped electrodes. Copper tungsten (70% W) for fine detail and high-precision EDM. High density, strength, thermal and electrical conductivity.

Tungsten
Tungsten carbide is used for cutting steel and WC. Small holes of deeper dimensions.

Workpiece and Tool Material

Electrical conductivity Less wear due to the spark (Low rw) Good machinability Good surface finish on w/p Tool Brass Brass Brass W/P Brass Hard C.S. WC rw 0.5 1.0 3.0

Loss of material from the tool Wear ratio rw = Loss of material from the work piece
rw increases with material hardness and decreases with the increase in melting point of the tool material.

Advantages
Any material that is electrically conductive can be cut Hardened work pieces can be machined eliminating the deformation caused by heat treatment. Complex dies sections and molds can be produced accurately, faster, and at lower costs. The EDM process is burr-free. Thin fragile sections such as webs or fins can be easily machined without deforming the part.

Disadvantages
High specific energy consumption (about 50 times that in conventional machining) When force circulation of dielectric is not possible, removal rate is quite low Surface tends to be rough for larger removal rates EDM process is not applicable to non-conducting materials

Applications
Mold and die making, slowly becoming a production process. Machining of difficult-to-machine materials. Miniature and fragile parts that can not withstand the force of conventional cutting. Holes of 0.05 mm, slots of 0.3 mm As EDM is a very slow process, it can be justified only where the hardness is too high or the features cannot be realized by other means. Tool making: sharp corners, small features, deep features etc. With the advent of hard cutting tools, full sinking is out of fashion. Removal of broken drills or fasteners Deep hole drilling of small holes. Eg.: turbine blades, fuel injection nozzles, inkjet printer head etc.

Wire-EDM

Wire EDM
This process is similar to contour cutting with a band saw. Slow moving wire travels along a prescribed path, cutting the work piece with discharge sparks. Wire should have sufficient tensile strength and fracture toughness. Wire is made of brass, copper or tungsten. (about 0.25mm in diameter).

Wire EDM
Process
Thin wire of as low as 0.03mm dia is used as the tool. For through features dies for punching, blanking and piercing; templates and profile gauges; extruder screws etc. Taper also possible Upto 4 axes available. Water is the common di-electric

WEDM machine classification

WEDM Process
Machining of hard and complex shapes with Sharp corners. Risk of wire breakage and bending has undermined the full potential of the process drastically reducing the efficiency and accuracy of the WEDM operation WEDM utilizes a continuously travelling wire electrode made of thin copper, brass or tungsten of diameter 0.05 0.3 mm, which is capable of achieving very small corner radii The material is eroded ahead of the wire and there is no direct contact between the workpiece and the wire, eliminating the mechanical stresses during machining Machining of EXOTIC and HSTR alloys

WEDM Process
The material removal mechanism of WEDM is very similar to the conventional EDM process involving the erosion effect produced by the electrical discharges (sparks) The WEDM process makes use of electrical energy generating a channel of plasma between the cathode and anode, and turns it into thermal energy at a temperature in the range of 800012,000 C or as high as 20,000 C A varying degree of taper ranging from15 degree for a 100 mm thick to 30 degree for a 400 mm thick workpiece can also be obtained on the cut surface. The microprocessor also constantly maintains the gap between the wire and the workpiece, which varies from0.025 to 0.05 mm

WEDM Process
Number of passes are required to achieve the required degree of accuracy and surface finish Dry WEDM (in gas) to achieve the high degree of surface finish The typical WEDM cutting rates (CRs) are 300 mm2/min for a 50 mm thick D2 tool steel and 750 mm2/min for a 150 mm thick aluminium , and SF quality is as fine as 0.040.25 Ra The deionised water is not suitable for conventional EDM as it causes rapid electrode wear, but its low viscosity and rapid cooling rate make it ideal for WEDM

Hybrid WEDM Process

WEDG machining of fine rods used in electronic circuits; machining of electrodes as small as 5 micron in diameter advantages of WEDG include the ability to machine a rod with a large aspect ratio, maintaining the concentricity of the rod and providing a wider choice of complex shapes such as tapered and stepped shapes at various sections. Ultrasonic Vibrations to wire to improve surface finish and cutting ratios Wire electrochemical grinding

WEDM Applications
Modern tooling applications - wafering of silicon and machining of compacting dies made of sintered carbide For dressing a rotating metal bond diamond wheel used for the precision form grinding of ceramics Advanced ceramic materials other common machining processes for machining ceramics are diamond grinding and lapping. Machining of boron carbide and silicon carbide MRR and surface roughness depends on processing parameters as well as workpiece material Machining of naturally non-conductor by doping with conducting material Machining of modern composite materials MMC and carbon fiber polymers

Major Research issues

WEDM process optimization Factors affecting performance measures pulse duration, discharge frequency and discharge current intensity Cutting ratio Factors affecting CR are properties of the workpiece material and dielectric fluid, machine characteristics, adjustable machining parameters, and component geometry. Use of DOE, ANN. It was found that the machining parameters such as the pulse on/off duration, peak current, open circuit voltage, servo reference voltage, electrical capacitance and table speed are the critical parameters for the estimation of the CR and SF. MRR - discharge current, pulse duration and pulse frequency are the significant control factors affecting the MRR and SF, while the wire speed, wire tension and dielectric flow rate have the least effect Surface finish all the electrical parameters have a significant effect on the surface finish

Major research issues

Wire EDM process monitoring and control
Fuzzy control system - proportional controls were used traditionally control the gap. Conventional control algorithms based on explicit mathematical and statistical models have been developed for EDM or WEDM operations Pulse discrimination system Knowledge system Ignition delay based system Wire breakage - rapid rise in frequency is observed before wire breaks; control strategy to switch off the generator at high frequency, localized high temperature causes wire breakage, excessive thermal force Wire material breakage and fracture Wire lag and wire vibrations- plasma and material erosion forces, hydraulic forces due to dielectric flow

Applications

The common applications of WEDM include the fabrication of the stamping and extrusion tools and dies, fixtures and gauges, prototypes, aircraft and medical parts, and grinding wheel form tools.

END

Micro-EDM processes

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Outline

Principle of EDM process Characteristics of EDM process Control of Discharge location Micro-manufacturing Scope of micromachining Classification of micromachining processes Role of micro-EDM in micromachining Micro-reverse EDM Research issues in micro-EDM related processes Experiments I micro-reverse EDM Future of micromachining

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Electrode gap monitoring and control

10 MHz

Mathematical adaptive control theory Advances in computer technology and advanced algorithms for machine control (Artificial intelligence, ANN)
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Micro-Manufacturing - What is it?

Manufacture of products with the following features:
about 100 m to about 10 mm in size contain very complex 3-D (free-form) surfaces employ a wide range of engineering materials possess extremely high relative accuracies in the 10-3 to 10-5 range
Micro-milling Fanuc - Japan

70 m - Human Hair 25 m - Characters

Zeiss - Germany Micro-parts

Micro-structures manufactured by micro-SLA Japan

Klocke Nanotechnik Micro-Motor

Micro-EDM NTU - Taiwan

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Why Miniaturization?
Minimizing energy and materials used for the manufacture of devices Integration with electronics; simplifying systems Cost/performance advantages Faster devices Increased selectivity and sensitivity Drawback-Size effect in mechanical micromachining

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Scope of micromachining processes

MICRO MACHINING
Micro Machining

Removal of material at micro level Macro components but material removal is at micro/nano level Micro/nano components and material removal is at micro/nano level Unfortunately, the present day notion is

Definition Material removal is micro/nano level with no constraint on the size of the component

Machining of highly miniature components with miniature features NOT CORRECT

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Classification of micromachining processes

FABRICATION

Macro-fabrication Hybrid Processes Mechanical - machining USM AJM AWJM WJM

Micro-fabrication Micro-machining -nano finishing

Beam energy based - machining EBM LBM EDM IBM PBM

Chem. & EC - machining PCMM ECMM

Micromachining processes
Energy Used

Principle Material removal via highly concentrated force Material removal via melting and/or vaporization and debris by high pressure gas

Processes and Features Cutting, grinding, sandblasting. UR ~ 100 nm, edge radius<1 m EDM, LBM, EBM. Small UR by reduced the pulse energy, concentration of energy via ultra short pulse duration and/or sharply focused beam by optics Excimer/Femto second laser. High dimensional accuracy, less HAZ but low machining speed and high cost of equipment Injection molding, die casting, etc. curing may be required after molding and porosity
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Mechanical Force Melting and vaporization

Ablation

Decomposition of atoms using incident photon energy or direct vaporization of material via high energy pulses Liquid or paste is solidified in a mold and shape of the mold is replicated

Solidification

Micromachining processes
Energy Used

Principle Chemical or electrochemical reaction based ionic dissolution Shape of the product specified by die/punch/mold

Processes and Features Chemical, PCM and ECM. Small UR, negligible force. Inter-electrode gap, flow of electrolyte influences accuracy Micro-punching, extrusion, etc. No UR is involved, high speed, spring-back and difficulties in die or mold making Stereolithography, internal as well as external profiles can be formed easily.

Dissolution

Plastic Deformation

Lamination

Material in solid powder or liquid form is solidified layerby-layer.

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Role of EDM in micromachining

Non-contact machining 3D machining Physical characteristics such as hardness, brittleness dose not affect the process Use of deionized water as dielectric Absence of Size Effect

80

Comparison of EDM and micro-EDM

The Resistance Capacitance Relaxation (RCrelaxation) circuit used in EDM is replaced by the RCpulse circuit in micro-EDM. In the RC-relaxation circuit, current and gap voltage are controlled at a pre-defined level throughout the pulse on-time but in modeling attempts in microEDM based on RC pulse circuits, the current and voltage are frequently assumed to be constant. On the other hand, in a single discharge of RC-pulse generator, the voltage and current are not maintained to any pre-defined level but depend upon the capacitor charge state at any instant. E = V I Duty cycle E = CV^2
81

Comparison of EDM and micro-EDM

EDM Circuitry Elements RC relaxation type Single spark process Forced process for constant voltage and current User defined pulse on time Interelectrode gap is 10s of m Low efficiency RC single pulse discharge Single spark process Single capacitance discharge, no const V and I No control gap characteristics Interelectrode gap is 1-5 m High efficiency Micro-EDM

Scaling Effects

Typical single spark crater

82

Micro-analysis of Debris
Large number of Spherical particles with few nonspherical particles Spherical particles are rich in workpiece material and non-spherical particles are rich in tool material Understanding of Erosion Mechanism and Oxide free power production Important parameters affecting Debris morphology are
Current

Voltage Pulse On-time Capacitance

Input Energy

Micro-analysis of Debris
Micro analysis reveals that there is movement of material from workpiece to cathode and vice-versa Normal distribution of particle size (Stochastic nature) Structures of Debris Large Size & Small Size Hollow & Solid Debris Satellite structure Hollow Spheres Dents Burnt Cores
Low Energy

High Energy

EDM process stability

Effect of Tool Rotation Effect of Ultrasonic Vibrations Effect of workpiece-tool material combination Effect of polarity PMEDM Effect of dielectric

How will you measure? Ignition delay time

Group Number Planetary Motion External material layer

Group 1 Yes Yes

Group 2 No Yes

Group 3 No No

Micro-EDM process stability

Indication of constantly moving spark Importance of eroded material in inter-electrode gap Discharge conduction through debris chain Effect on surface cracks Process stability primarily depends on discharge transitivity rather than breakdown strength Yo et al. Absence of metallic particles can be one of the causes of arching

1 Low energy 2 High Energy

Variants of micro-EDM

Figure : Micro rods machining processes

Process
BEDG Micro-WEDG Micro-WEDM

Capability
Min. 3 m diameter electrode, maximum 10 aspect ratio, 0.6 Ra surface finish Min. 5 m diameter electrode, maximum 10 aspect ratio, 0.8 Ra surface finish Best results obtained are 10x10 square array (23 m width, 700 m height), minimum machining size achievable is 20 m, surface finish 0.07-0.35 m Ra, and maximum aspect ratio 100 micro tower of 1 mm in height and 25 m square

Limitation
Only single electrodes can be machined Cylindrical electrodes as well as arrayed electrodes cant be machined Cylindrical arrayed structures cant be machined

Diamond milling

Mechanical process involves machining 87 87 stresses

Research issues in micro-EDM

Micro-EDM Research Areas
Handling Electrode and workpiece preparation Off-machine electrode preparation Drilling, threading holes (WEDM) Machining Process Process Parameters Sources of Errors Machine Electrode Jigs and Fixture Electrode wear and machining strategies Multi electrode Wear monitoring system 88 Measurement Surface quality Dimensions

Electrode Parts

Mfg. Micro 3D electrode

On-machine electrode Rotating Disk Stationery block Guided running wire

Uniform wear method

Z-compensation

Applications
Machining of mould and die in high strength materials (Carbides, die steel, conducting ceramics) Recently replaced by high speed milling process Chemical aspects of EDM
Production of fine particle powders RESA (for ultrafine powders)- Reactive Electrode Submerged Arc EDM Diamond like carbon and nano-tubes (solidification of evaporated material) Large amount of energy is consumed in the chemical action during EDM Supplying oxygen can enhance the MRR during the process

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Machining of arrayed micro-structures by REDM

Reverse replication of

aa) Normal EDM

Bulk Rod

ab) Reverse EDM

Micro-rods

Figure : Working of micro and reverse micro EDM processes

arrayed hole on the plate electrode to the bulk material by change in the polarity Machined structures have a dimensions equal to the original dimension of pocket minus interelectrode gap Important operating parameters are voltage , capacitance, threshold, and the feed

Figure : a) array of 4 microrod machined, b) plate used as a tool during machining

90

Machining of arrayed micro-structures by REDM

Problem Statement : Machining of high aspect ratio arrayed microstructures by micro reverse EDM process.

Figure : set up of the micro-REDM process

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Applications of micro-REDM
Applications

Mechanical
Micromachining As a electrode in arrayed hole/cavity machining Mask preparation As a tool for generating stable plasma Heat Exchanging Hexagonal and thin wall structures Automobile Micronozzels

MEMS
Arrayed holes for passing wires in MEMS devices Thin wall structures as a cooling devices in MEMS system Shaft for micro robots micro actuator

Biomedical
As a interface device for capturing neural signals Brain neural activity recording Arrayed microholes as a spray nozzels in the biotechnology applications Microneedels- syringe Holding sights for the testing reagents

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Components fabricated by micro-REDM

93

Reverse-micro Wire EDM

94

Experiments in micro-REDM

Workpiece geometry : Machining of 400 m square and 200 m cylindrical electrodes, machined length 1 mm

Images of the micro rods machined in each run of experiment

95

Surface Morphology
Root Surface

Surface near tip exhibits number of craters , whereas the surface at the root is relatively smooth. Smooth surface with almost no pits is observed near the root in the magnified image of fabricated structure
Tip Surface

Sample 3
A

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Arrayed structures machined at MTL IIT Bombay

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