Skip to main content
SpringerLink
Log in

An Analysis of the Uneven Tool Electrode Wear Mechanism in the Micro-electrical Discharge Machining Process

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing-Green Technology Aims and scope Submit manuscript

Abstract

Micro-electrical discharge machining (micro-EDM) has an issue of uneven tool electrode wear that seriously affects the micro-hole accuracy. However, the mechanism of uneven tool electrode wear remains unclear. In this study, the uneven tool electrode wear mechanism has been studied both theoretically and experimentally. It was first discovered that the ultrafine debris particles produced by the EDM spark play a critical role in uneven tool electrode wear. A theoretical model was established to reveal the movement and the distribution of the debris by employing Einstein’s tea leaf paradox i.e., classic secondary flow theory and the electrophoretic theory. According to this model, when the polarity is positive, the ultrafine debris aggregates gradually and adheres onto  the bottom of the micro-hole, thereby  a debris layer of a parabolic profile is formed progressively. This dynamic debris layer shields the material to be removed by the EDM spark. As a result, the tip of the tool electrode is unevenly worn into a conical concavity shape. Conversely, under negative polarity, the tip of the tool electrode is unevenly worn into a conical shape. A set of experiments was performed to verify the model and the results agreed well with the predicted  phenomena. Subsequently, a novel approach is  proposed to eliminate the uneven tool electrode wear by reversing pulse polarity in a repetitive manner. Using this method, uneven tool electrode wear can be avoided and high accuracy micro-holes without the features of a cone and/or conical concavity can be obtained.

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.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability statement

The data used to support the findings of this study have not been made available.

References

  1. Masuzawa, T. (2000). State of the art of micromachining. CIRP Annals-Manufacturing Technology, 49, 473–488.

    Article  Google Scholar 

  2. Hasan, M., Zhao, J., & Jiang, Z. (2017). A review of modern advancements in micro drilling techniques. Journal of Manufacturing Processes, 29, 343–375.

    Article  Google Scholar 

  3. Chu, W. S., Kim, C. S., Lee, H. T., Choi, J. O., Park, J. I., Song, J. H., Jang, K. H., & Ahn, S. H. (2014). Hybrid manufacturing in micro/nano scale: A Review. International Journal of Precision Engineering and Manufacturing-Green Technology, 1(1), 75–92.

    Article  Google Scholar 

  4. Nasrollahi, V., Penchev, P., Batal, A., Le, H., Dimov, S., & Kim, K. (2020). Laser drilling with a top-hat beam of micro-scale high aspect ratio holes in silicon nitride. Journal of Materials Processing Technology, 281, 116636.

    Article  Google Scholar 

  5. Heo, J., Min, H., & Lee, M. (2015). Laser micromachining of permalloy for fine metal mask. International Journal of Precision Engineering and Manufacturing-Green Technology, 2(3), 225–230.

    Article  Google Scholar 

  6. Chen, X., Zhu, J., Xu, Z., & Su, G. (2021). Modeling and experimental research on the evolution process of micro through-slit array generated with masked jet electrochemical machining. Journal of Materials Processing Technology, 298, 117304.

    Article  Google Scholar 

  7. Chung, D. K., & Chu, C. N. (2015). Effect of inductance in micro EDM using high frequency bipolar pulse generator. International Journal of Precision Engineering and Manufacturing-Green Technology, 2(3), 299–303.

    Article  Google Scholar 

  8. Islam, M. M., Li, C. P., & Ko, T. J. (2017). Dry electrical discharge machining for deburring drilled holes in CFRP composite. International Journal of Precision Engineering and Manufacturing-Green Technology, 4(2), 194–154.

    Article  Google Scholar 

  9. Zia, M. K., Pervaiz, S., Anwar, S., & Samad, W. A. (2019). Reviewing sustainability interpretation of electrical discharge machining process using triple bottom line approach. International Journal of Precision Engineering and Manufacturing-Green Technology, 6(5), 931–945.

    Article  Google Scholar 

  10. Tsai, Y. Y. (2004). An index to evaluate the wear resistance of the electrode in micro-EDM. Journal of Materials Processing Technology, 149(1–3), 304–309.

    Article  Google Scholar 

  11. Li, G., Natsu, W., & Yu, Z. (2019). Study on quantitative estimation of bubble behavior in micro hole drilling with EDM. International Journal of Machine Tools and Manufacture, 146, 103437.

    Article  Google Scholar 

  12. Ferraris, E., Castiglioni, V., Ceyssens, F., Annoni, M., Lauwers, B., & Reynaerts, D. (2013). EDM drilling of ultra-high aspect ratio micro holes with insulated tools. CIRP Annals-Manufacturing Technology, 62(1), 191–194.

    Article  Google Scholar 

  13. Wang, Y., Zhao, F., & Jin, W. (2009). Wear-resist electrodes for micro-EDM. Chinese Journal of Aeronautics, 22(3), 339–342.

    Article  Google Scholar 

  14. Kumar, R., & Singh, I. (2019). A modified electrode design for improving process performance of electric discharge drilling. Journal of Materials Processing Technology, 264, 211–219.

    Article  Google Scholar 

  15. D’Urso, G., Longo, M., Maccarini, G., & Ravasio, C. (2011). Electrical discharge machining of micro holes on titanium sheets. In Proceedings of the ASME Design Engineering Technical Conference (pp. 417–424).

  16. Jahan, M. P., Wong, Y. S., & Rahman, M. (2009). A study on the quality micro-hole machining of tungsten carbide by micro-EDM process using transistor and RC-type pulse generator. Journal of Materials Processing Technology, 209(4), 1706–1716.

    Article  Google Scholar 

  17. Yan, M.-T., Fang, G.-R., & Yi-Ting, L. (2013). An experimental study on micro wire-EDM of polycrystalline diamond using a novel pulse generator. International Journal of Advanced Manufacturing Technology, 66, 1633–1640.

    Article  Google Scholar 

  18. Yang, J., Yang, F., Hua, H., Cao, Y., Li, C., & Fang, B. (2018). A bipolar pulse power generator for micro-EDM. Procedia CIRP, 68, 620–624.

    Article  Google Scholar 

  19. Huan, L., Jicheng, B., Yan, C., Guozheng, Z., & Shaojie, H. (2020). Micro-electrode wear and compensation to ensure the dimensional consistency accuracy of micro-hole array in micro-EDM drilling. International Journal of Advanced Manufacturing Technology, 111(9–10), 2653–2665.

    Article  Google Scholar 

  20. Mustafa, Ay., Ulaş, Ç., & Ahmet, H. (2013). Optimization of micro-EDM drilling of inconel 718 superalloy. International Journal of Advanced Manufacturing Technology, 66(5–8), 1015–1023.

    Google Scholar 

  21. Pei, J., Zhang, L., Du, J., Zhuang, X., Zhou, Z., Wu, S., & Zhu, Y. (2017). A model of tool wear in electrical discharge machining process based on electromagnetic theory. International Journal of Machine Tools and Manufacture, 117, 31–41.

    Article  Google Scholar 

  22. Jeong, Y. H., & Min, B. K. (2007). Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. International Journal of Machine Tools and Manufacture, 47(12–13), 1817–1826.

    Article  Google Scholar 

  23. Aligiri, E., Yeo, S. H., & Tan, P. C. (2010). A new tool wear compensation method based on real-time estimation of material removal volume in micro-EDM. Journal of Materials Processing Technology, 210(15), 2292–2303.

    Article  Google Scholar 

  24. Malayath, G., Katta, S., Sidpara, A., & Deb, S. (2019). Length-wise tool wear compensation for micro electric discharge drilling of blind holes. Measurement, 134, 888–896.

    Article  Google Scholar 

  25. Pham, D. T., Ivanov, A., Bigot, S., Popov, K., & Dimov, S. (2007). An investigation of tube and rod electrode wear in micro EDM drilling. International Journal of Advanced Manufacturing Technology, 33(1–2), 103–109.

    Article  Google Scholar 

  26. Mitsui, K., & Mahardika, M. (2008). A new method for monitoring micro-electric discharge machining process. International Journal of Machine Tools and Manufacture, 48(3–4), 446–458.

    Google Scholar 

  27. Ekmekci, B., Sayar, A., Opöz, T. T., & Erden, A. (2009). Geometry and surface damage in micro electrical discharge machining of micro-holes. Journal of Micromechanics and Microengineering, 19, 105030.

    Article  Google Scholar 

  28. Schacht, B., Kruth, J., Lauwers, B., & Vanherck, P. (2004). The skin-effect in ferromagnetic electrodes for wire-EDM. International Journal of Advanced Manufacturing Technology, 23(11–12), 794–799.

    Google Scholar 

  29. Li, X., Wang, Y., Liu, Y., & Zhao, F. (2019). Research on shape changes in cylinder electrodes incident to micro-EDM. Advances in Materials Science and Engineering, 2019(4), 1–11.

    Google Scholar 

  30. Ekmekci, B., & Sayar, A. (2013). Debris and consequences in micro electric discharge machining of micro-holes. International Journal of Machine Tools and Manufacture, 65, 58–67.

    Article  Google Scholar 

  31. Ichikawa, T., & Natsu, W. (2013). Investigation of machining characteristics of micro-EDM with ultrasonically vibrated machining fluid under ultra-small discharge energy. International Journal of Electrical Machining, 18, 1–7.

    Article  Google Scholar 

  32. Ikeno, J., Tani, Y., & Sato, H. (1990). Nanometer grinding using ultrafine abrasive pellets—manufacture of pellets applying electrophoretic deposition. CIRP Annals-Manufacturing Technology, 39(1), 341–344.

    Article  Google Scholar 

  33. Mangelsdorf, C. S., & White, L. R. (1992). Electrophoretic mobility of a spherical colloidal particle in an oscillating electric field. Journal of the Chemical Society Faraday Transactions, 88(24), 3567–3581.

    Article  Google Scholar 

  34. Einstein, A. (1926). Die ursache der manderbildung der flulufe und des sogenannten baerschen gesetze. Naturwissenschaften, 14(11), 223–224.

    Article  Google Scholar 

Download references

Acknowledgements

The work described in this study was supported by the National Natural Science Foundation of China (Grant nos. 52175387 and 52075104). We sincerely thank Xinlang Zuo for their support with the SEM and EDS (the China Electronic Product Reliability and Environmental Testing Research Institute).

Author information

Authors and Affiliations

  1. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, 510006, People’s Republic of China

    Zhixiang Zou, Zhongning Guo & Jiangwen Liu

  2. College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, People’s Republic of China

    Xiaoyu Zhang & Can Weng

  3. Department of Industrial and Systems Engineering, Research Institute for Advanced Manufacturing, The Hong Kong Polytechnic University, Hung Hom, Hong Kong

    Kangcheung Chan & Taiman Yue

Authors
  1. Zhixiang Zou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xiaoyu Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kangcheung Chan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Taiman Yue
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhongning Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Can Weng
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Jiangwen Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jiangwen Liu.

Ethics declarations

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zou, Z., Zhang, X., Chan, K. et al. An Analysis of the Uneven Tool Electrode Wear Mechanism in the Micro-electrical Discharge Machining Process. Int. J. of Precis. Eng. and Manuf.-Green Tech. 10, 1375–1391 (2023). https://doi.org/10.1007/s40684-022-00499-9

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40684-022-00499-9

Keywords

Search

Navigation