Skip to main content
SpringerLink
Log in

Towards the effective tool wear control in micro-EDM milling

  • SPECIAL ISSUE - ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The electrode wear in micro-electrical discharge milling (micro-EDM milling) is one of the main problems to be solved in order to improve machining accuracy. This paper presents an investigation on wear and material removal in micro-EDM milling for selected process parameter combinations typical of rough and finish machining of micro-features in steel. The experiments were performed on state-of-the-art micro-EDM equipment. Based on discharge counting and volume measurements, electrode wear per discharge and material removal per discharge were measured for several energy levels. The influence of the accuracy of volume measurements on the electrode wear per discharge and on the material removal per discharge are discussed, and the issues limiting the applicability of real time wear sensing in micro-EDM milling are presented.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. Rajurkar KP, Levy G, Malshe A, Sundaram MM, McGeough J, Hu X, Resnick R, De Silva A (2006) Micro and nano machining by electro-physical and chemical processes. Ann CIRP 55(2):643–666. doi:10.1016/j.cirp. 2006.10.002

    Article  Google Scholar 

  2. Rajurkar KP, Yu ZY (2000) 3D micro-EDM using CAD/CAM. Ann CIRP 49(1):129–130. doi:10.1016/S0007-8506(07)62911-4

    Article  Google Scholar 

  3. Egashira K, Matsugasako A, Tsuchiya H, Miyazaki M (2006) Electrical discharge machining with ultralow discharge energy. Precis Eng 30(4):414–420. doi:10.1016/j.precisioneng.2006.01.004

    Article  Google Scholar 

  4. Bleys P, Kruth J-P, Lauwers B (2004) Sensing and compensation of tool wear in milling EDM. J Mater Process Technol 149:139–146. doi:10.1016/j.jmatprotec.2003.11.042

    Article  Google Scholar 

  5. Bleys P, Kurth JP, Lauwers B, Zryd A, Delpretti R, Tricarico C (2002) Real-time tool wear compensation in milling EDM. Ann CIRP 51(1):157–160. doi:10.1016/S0007-8506(07)61489-9

    Article  Google Scholar 

  6. Yu ZY, Masuzawa T, Fujino M (1998) Micro-EDM for three-dimensional cavities—development of uniform wear method. CIRP Ann 47(1):169–172. doi:10.1016/S0007-8506(07)62810-8

    Article  Google Scholar 

  7. Pham DT, Dimov SS, Bigot S, Ivanov A, Popov K (2004) Micro-EDM—recent developments and research issues. J Mater Process Technol 149(1–3):50–57

    Article  Google Scholar 

  8. Lim HS, Son SM, Wong YS, Rahman M (2007) Development and evaluation of an on-machine optical measurement device. International Journal of Machine Tools and Manufacture 47(10):1556–1562

    Article  Google Scholar 

  9. Van Dijck F (1973) Physico-mathematical analysis of the electro discharge machining process. Ph.D. thesis, Katholieke Universiteit Leuven

  10. Xia H, Kunieda M, Nishiwaki N (1996) Removal amount difference between anode and cathode in EDM process. IJEM 6:19–26

    Google Scholar 

  11. Kunieda M, Lauwers B, Rajurkar KP, Schumacher BM (2005) Advancing EDM through fundamental insight into the process. Ann CIRP 54(2):599–622. doi:10.1016/S0007-8506(07)60020-1

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Innovation in Mechanics and Management (DIMEG), University of Padova, Via Venezia 1, Padova, 35131, Italy

    G. Bissacco

  2. Laboratory for Alternative Technologies, Faculty of Mechanical Engineering, University of Ljubljana, Ljubljana, Slovenia

    J. Valentincic

  3. Department of Mechanical Engineering (MEK), Technical University of Denmark (DTU), Kgs. Lyngby, Denmark

    H. N. Hansen & B. D. Wiwe

Authors
  1. G. Bissacco
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Valentincic
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. N. Hansen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. B. D. Wiwe
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to G. Bissacco.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Bissacco, G., Valentincic, J., Hansen, H.N. et al. Towards the effective tool wear control in micro-EDM milling. Int J Adv Manuf Technol 47, 3–9 (2010). https://doi.org/10.1007/s00170-009-2057-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-009-2057-0

Keywords

Search

Navigation