Spark location adaptive process control in meso-micro EDM

Time-synchronised high-speed imaging and electrical signal measurements are performed in near-real erosion conditions to analyse the feasibility of determining spark location based on its electrical signals in die-sinking electrical discharge machining (EDM). Using this novel research platform, a correlation between the discharge voltage and the geometric location of a discharge on an electrode has been established. Through the derived understanding, a microsecond level spark location adaptive process control has been conceptualised and demonstrated. The parameter control of each spark according to its probabilistic location on the electrode results in low wear of micro- to macroscale electrode features, higher material removal rate and higher form precision despite of electrode complexity. Reduction in the required number of electrodes achieved through the novel spark location adaptive process control increases the economic and energy efficiency of die-sinking EDM

Spark location adaptive process control in meso-micro EDM

Time-synchronised high-speed imaging and electrical signal measurements are performed in near-real erosion conditions to analyse the feasibility of determining spark location based on its electrical signals in die-sinking electrical discharge machining (EDM). Using this novel research platform, a correlation between the discharge voltage and the geometric location of a discharge on an electrode has been established. Through the derived understanding, a microsecond level spark location adaptive process control has been conceptualised and demonstrated. The parameter control of each spark according to its probabilistic location on the electrode results in low wear of micro- to macroscale electrode features, higher material removal rate and higher form precision despite of electrode complexity. Reduction in the required number of electrodes achieved through the novel spark location adaptive process control increases the economic and energy efficiency of die-sinking EDM.ISSN:0268-3768ISSN:1433-301

Super-finished Surfaces using meso-micro EDM

A novel stochastic orbiting strategy combined with extremely low stray capacitance sinking EDM machine offers the capability to achieve super-finished surfaces (Ra <0.1 μm) without pre-polishing of the copper tool electrodes. Surface defects such as inhomogeneity, cracks, arc spots and black spots have been analysed and reduced, while improving material removal rate with lower tool wear. Super-finished surfaces thus generated have uniform white layer (re-solidified layer) with an average thickness below 1 μm. Unlike mirror finishing using EDM with powder mixed dielectric, absence of the additives in dielectric results in smaller gap width during finishing, delivering sub-micron accuracy of the machined features. With the tool electrodes machined using conventional machining techniques such as milling, turning or wire-EDM having surfaces with Ra ≤ 0.2 μm, advamcements of the work offers manufacturing industry an economic and energy efficient super-finishing process, especially in meso-micro scale.ISSN:2212-827

Spark location adaptive process control in meso-micro EDM

ISSN:0268-3768ISSN:1433-301