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Article

An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling

by 1,2, 2, 1,*, 1 and 2
1
Shanghai Engineering Research Center of Ultra-Precision Optical Manufacturing, School of Information Science and Technology, Fudan University, Shanghai 200438, China
2
Institute of Machinery Manufacturing Technology, China Academy of Engineering Physics, Mianyang 621000, China
*
Author to whom correspondence should be addressed.
Academic Editors: Irene Fassi and Francesco Modica
Micromachines 2021, 12(6), 711; https://doi.org/10.3390/mi12060711
Received: 26 May 2021 / Revised: 9 June 2021 / Accepted: 14 June 2021 / Published: 17 June 2021
In micro-electrical discharge machining (micro-EDM) milling, the cross-section of the microgroove machine is frequently not an ideal rectangle. For instance, there are arc shapes on the bottom and corners, and the sidewall is not steep. The theoretical explanation for this phenomenon is still lacking. In addition to the tip discharge effect, the essential reason is that there is an accumulative difference in time and space during the shape change process of a tool electrode and the microstructure formation on a workpiece. The process parameters are critical influencing factors that determine this accumulative difference. Therefore, the accumulative difference mechanism in time and space is investigated in this paper, and then a theoretical model is developed to simulate the micro-EDM milling process with a straight-line single path. The simulation results for a cylindrical electrode at the two rotational speeds of 0 (nonrotating) and 300 rpm are compared, while the results for a cylindrical electrode and a square electrode at a rotation speed of 0 are also compared to verify that different process parameters generate accumulative differences in the time and space of material removal. Finally, micro-EDM milling experiments are carried out to verify the simulation model. The maximum mean relative deviation between the microgroove profiles of simulation results and those of experiments is 11.09%, and the profile shapes of simulations and experiments have a good consistency. A comparative experiment between a cylindrical electrode and a hollow electrode is also performed, which further verifies the mechanism revealed in the study. Furthermore, the cross-section profile of a microgroove can be effectively controlled by adjusting the process parameters when utilising these accumulative differences through fabricating a microgroove with a V-shaped cross-section by a square electrode and a microgroove with a semi-circular cross-section by a cylindrical electrode. This research provides theoretical guidance for solving the problems of the machining accuracy of detail features in micro-EDM milling, for instance, to machine a microgroove with an ideal rectangular cross-section. View Full-Text
Keywords: micro-EDM milling; accumulative difference; material removal; tool electrode wear micro-EDM milling; accumulative difference; material removal; tool electrode wear
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MDPI and ACS Style

Jing, Q.; Zhang, Y.; Kong, L.; Xu, M.; Ji, F. An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling. Micromachines 2021, 12, 711. https://doi.org/10.3390/mi12060711

AMA Style

Jing Q, Zhang Y, Kong L, Xu M, Ji F. An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling. Micromachines. 2021; 12(6):711. https://doi.org/10.3390/mi12060711

Chicago/Turabian Style

Jing, Qi, Yongbin Zhang, Lingbao Kong, Min Xu, and Fang Ji. 2021. "An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling" Micromachines 12, no. 6: 711. https://doi.org/10.3390/mi12060711

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