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Micro-electrode wear and compensation to ensure the dimensional consistency accuracy of micro-hole array in micro-EDM drilling

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Abstract

The micro-hole array machined by microelectrical discharge machining (micro-EDM) has been widely used in industrial fields, such as inkjet nozzle, oil nozzle, spinneret, and so on. However, it is difficult to guarantee the dimensional consistency accuracy of micro-hole array. In the present study, the characteristic and compensation strategy of microelectrode wear were explored to meet the requirements of dimensional consistency accuracy of micro-hole array machining. The effect of pulse generator parameters on microelectrode wear was studied, and the microelectrode wear was reduced by optimizing pulse generator parameters. The geometry evolution rule of microelectrode was investigated, and the microelectrode wear model was established based on the wear characteristic of microelectrode. By analyzing the wear characteristic of microelectrode, single-hole quantitative compensation strategy was adopted during the machining process. Meanwhile, grouping detection variable compensation strategy was proposed to adjust axial position of microelectrode periodically in order to eliminate the cumulative compensation errors. The array of 256 (16 × 16) micro-holes with an average diameter of 45.28 μm was machined on a 50-μm-thick stainless steel. The dimensional consistency accuracy of micro-hole array was assured by showing a standard deviation of 0.15 μm. In addition, the array of 64 (8 × 8) micro-holes and the array of 25 (5 × 5) micro-holes with an average diameter of less than 20 μm were machined to explore the performance of micro-hole array machining with smaller size, and the dimensional consistency accuracy was shown by the standard deviation of 0.25 and 0.4 μm, respectively.

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Funding

This project is supported by the National Natural Science Foundation of China (No. 51575137), the Key Project of Natural Science Foundation of Heilongjiang Province of China (No. ZD2019E005), and the National Natural Science Foundation of China (No. 51975156).

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Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, No.92 West Dazhi Street, Nangang District, Harbin, 150001, Heilongjiang, China

    Liu Huan, Bai Jicheng, Cao Yan, Zhu Guozheng & Hou Shaojie

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  1. Liu Huan
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  2. Bai Jicheng
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  3. Cao Yan
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  4. Zhu Guozheng
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  5. Hou Shaojie
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Correspondence to Bai Jicheng.

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Huan, L., Jicheng, B., Yan, C. et al. Micro-electrode wear and compensation to ensure the dimensional consistency accuracy of micro-hole array in micro-EDM drilling. Int J Adv Manuf Technol 111, 2653–2665 (2020). https://doi.org/10.1007/s00170-020-05811-y

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