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Experimental study on the influence of workpiece shape on discharge gap and burr in LS-WEDM and the preparation of microelectrode array with specific size

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Abstract

Microelectrode array has significant and diverse applications in contemporary technology. The most effective method for the precise manufacture of micro-electrode array with specific dimensions is low-speed wire electrical discharge machining (LS-WEDM) combined with workpiece rotation. Workpiece rotation results in the transformation of the machined part from a continuum to a thin-walled array of discontinuities. The change in workpiece structure influences the machining performance. This paper investigates the impact of workpiece thickness and the thin-walled array of workpieces on the discharge gap and burr of LS-WEDM for different materials (copper, copper-tungsten alloy, and pure tungsten). The results show that the discharge gap of thin-walled array depends on the distance between the top and bottom of the workpiece and the number of arrays, while the burr width of thin-walled array depends on the thickness of the individual thin-walled units. In addition, a formula for the discharge gap of a thin-walled array workpiece is given. Based on this, microelectrode array with a side length of 300 μm and a size error of less than 3 μm are prepared on three materials by compensating the machining gaps corresponding to each position, and the surface quality of microelectrode array is evaluated. This study has crucial implications for improving the dimensional accuracy of microelectrode array produced by LS-WEDM.

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Funding

This study is funded by the Fundamental Research Funds for the Central Universities (N2303001) and the National Natural Science Foundation of China (No.U1908230, No.52005092).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, People’s Republic of China

    Liya Jin, Yadong Gong, Yantong Hu, Yao Sun & Chunyou Liang

Authors
  1. Liya Jin
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  2. Yadong Gong
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  3. Yantong Hu
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  4. Yao Sun
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  5. Chunyou Liang
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Contributions

L.Y. Jin: investigation, methodology, experiment, writing—original draft. Y.T. Hu: experiment. S. Yao and C.Y. Liang: conceptualization. Y.D. Gong: funding acquisition, reviewed and edited the manuscript, supervision.

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Correspondence to Yadong Gong.

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Jin, L., Gong, Y., Hu, Y. et al. Experimental study on the influence of workpiece shape on discharge gap and burr in LS-WEDM and the preparation of microelectrode array with specific size. Int J Adv Manuf Technol 130, 5965–5977 (2024). https://doi.org/10.1007/s00170-024-13106-9

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