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Concept development for fabricating threaded micro-pin using wire-EDM

  • Tapas DebnathEmail author
  • Promod Kumar Patowari
Technical Paper
  • 54 Downloads

Abstract

Nowadays miniaturization with precision is an important requirement in the field of medical devices and high-end applications. This work introduces the concept of 3D complex geometry fabrication in microscale using typical 2-Axis wire-cut electric discharge machine (WEDM). In this regard, the threaded profile micro-pin has been chosen in the present study. Synchronizing the workpiece rotating speed with feed rate along with a suitable depth of cut is the required condition for fabricating a screw. A separate attachment has been developed and used to rotate the workpiece at different speeds. Further, a CNC code has been generated to design the tool path with the required tool feed and depth of cut. Initially, turning operation has been performed which results in reduction in the tool diameter into the desired dimension along with the elimination of the eccentricity of the rotating rod. Consequently, the thread cutting operation has been accomplished with the adjusted set of parameters. Besides, the surface topography and material characteristics of the fabricated screw fin have also been observed based on scanning electron microscopic images and energy-dispersive X-ray analysis. Finally, the established process has been escalated further to fabricate screws of minimum possible dimension using the WEDM.

Keywords

Micro-screw Turning Thread cutting WEDM Micro-pin 

List of symbols

α

Thread angle

D1

Major diameter of the screw

D2

Minor diameter of the screw

F

Wire feed

I

Peak current

L

Length of the screw

m

Number of threads starts in a screw

n

Number of turn in a screw

P

Pitch

r

Radius of the semicircular thread

S

Table feed

SS

Spindle speed

T

Machining time

Ton

Pulse-on-time

Toff

Pulse-off-time

V

Voltage

v

Volume

Abbreviations

2D

Two dimensional

3D

Three dimensional

µEDM

Micro-electrical discharge machining

CNC

Computer numerical control

DC

Direct current

EDM

Electrical discharge machining

EDX

Energy-dispersive x-ray

EJT

Electrolytic jet turning

MRR

Material removal rate

RPM

Revolution per minute

SEM

Scanning electron microscope

TPC

Teeth per centimeter

WECM

Wire electrochemical machining

WEDG

Wire electrical discharge grinding

WEDM

Wire electrical discharge machining

WEDT

Wire electrical discharge turning

WEDTC

Wire electrical discharge thread cutting

Notes

References

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Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringNIT SilcharSilcharIndia

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