Skip to main content

Advertisement

SpringerLink
Log in

High-aspect ratio micro-pin manufacturing using inverse slab electrical discharge milling (ISEDM) process

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

Abstract

Manufacturing of micro-pins with diameter less than 1 mm is a field of great interest both in research and in industrial application. There is a wide variety of components of low-diameter cylindrical geometry for various applications, including precision products such as gear shafts, valves, shafts, and channels of micro-fluidic systems, parts for micro-pumps and turbines, etc. Increasing interest can also be found in the manufacturing of micro-electrodes for micro-hole EDM drilling of Ti- and Ni-base alloys for the aerospace industry. The inverse slab electrical discharge milling (ISEDM) process has been recently proposed as an economical alternative for the manufacturing of high-aspect ratio low-diameter cylindrical parts. However, application of the process requires understanding the influence of the process variables. The technological data given by conventional SEDM machines (static workpiece) are not valid for this process due to the relative rotation movement of the part with respect to the electrode. In this work, a systematic study of the influence of the process variables on the efficiency of the ISEDM process is presented. The geometrical characteristics of the cylindrical part, its rotational speed, and the energy of the discharge have been included in the study as main input variables. Their effect on material removal rate, surface finish, and micropin accuracy is discussed. Results show that micropins of aspect ratio as high as 90:1 and 0.2 mm diameter can be economically manufactured.

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

Similar content being viewed by others

References

  1. Masuzawa T (2000) State of the art of micromachining. Ann CIRP 49(2):473–488

    Article  Google Scholar 

  2. Fan ZW, Hourng LW (2009) The analysis and investigation on the microelectrode fabrication by electrochemical machining. Int J Mach Tools Manuf 49:659–666

    Article  Google Scholar 

  3. Huang CA, Chang JH, Yang SY, Yang CC (2006) Preparation of a needle probe with sharp tip and high aspect ratio geometry by an electrochemical etching method. Corros Sci 48:4294–4302

    Article  Google Scholar 

  4. Mao-Sheng L, Guan-Xin C, Zhen-Long W, Yu-Kui W, Li D (2009) Micro electrical discharge machining of small hole in TC4 alloy. Trans Nonferrous Met Soc China 19:434–439

    Article  Google Scholar 

  5. Liu H-S, Yan B-H, Huang F-Y, Qiu K-H (2005) A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications. J Mater Process Technol 169:418–426

    Article  Google Scholar 

  6. Kawakami K, Kunieda M (2005) Study on factors determining limits of minimum machinable size in micro EDM. Ann CIRP 54(1):167–170

    Article  Google Scholar 

  7. Hattori R (2006) Ultra-precision micromachining using linear-motor-driven EDM machines. Die Mould Technol 21(6):28–31

    MathSciNet  Google Scholar 

  8. Egashira K, Mizutani K (2005) EDM at low open-circuit voltage. Int J Electr Mach 10:21–26

    Google Scholar 

  9. Egashira K, Morita Y, Hattori Y (2010) Electrical discharge machining of submicron holes using ultrasmall-diameter electrodes. Precis Eng 34:139–144

    Article  Google Scholar 

  10. DeMello AJ, Wootton RCR (2009) Miniaturization: chemistry at the crossroads. Nat Chem 1:28–29

    Article  Google Scholar 

  11. Zhang M, Wu J, Wang L, Xiao K, Wen W (2010) A simple method for fabricating multi-layer PDMS structures for 3D microfluidic chips. Lab Chip 10:1199

    Article  Google Scholar 

  12. Song S, Lee C, Kim T, Shin I, Jun S, Jung H (2010) A rapid and simple fabrication method for 3-dimensional circular microfluidic channel using metal wire removal process. Microfluid Nanofluid 9(2–3):533–540

    Article  Google Scholar 

  13. Morarka A, Agrawal S, Kale S, Kale A, Ogale S, Paknikar K, Bodas D (2011) Quantum dot based immunosensor using 3D circular microchannels fabricated in PDMS. Biosens Bioelectron 26:3050–3053

    Article  Google Scholar 

  14. Jurischka R, Schoth A, Müller C, Thiebaud D, Gallera R, Reinecke H (2006) Hard tooling by μ-EDM milling for injection moulding. Multi-Material Micro Manufacture

  15. Chern G, Wu YE, Cheng J, Yao J (2007) Study on burr formation in micro-machining using micro-tools fabricated by micro-EDM. Precis Eng 31:122–129

    Article  Google Scholar 

  16. Masuzawa T, Fujino M, Kobayashi K (1985) Wire electro-discharge grinding for micro-machining. Ann CIRP 34(1):431–435

    Article  Google Scholar 

  17. Uhlman E, Piltz S, Oberschmidt D (2008) Machining of micro rotational parts by wire electrical discharge grinding. Prod Eng Res Dev 2:227–233

    Article  Google Scholar 

  18. Egashira K, Hosono S, Takemoto S, Masao Y (2011) Fabrication and cutting performance of cemented tungsten carbide micro-cutting tools. Precis Eng 35:547–553

    Article  Google Scholar 

  19. Bhavsar SN, Aravindan S, Rao PV (2009) A critical review of micro-tools fabrication by focused ion beam (FIB) technology, vol II. Proc. World Congress on Engineering, London

    Google Scholar 

  20. Onikura H, Onishi O, Take Y, Kobayashi A (2000) Fabrication of micro carbide tools by ultrasonic vibration grinding. Ann CIRP 49(1):257–260

    Article  Google Scholar 

  21. Rajurkar KP, Levy G, Malshe A, Sundaram MM, McGeough J, Ul X, Resnick R, DeSilva A (2006) Micro and nano machining by electro-physical and chemical processes. Annals of the CIRP55 (1):643–666

  22. Uhlmann E, Piltz S, Jerzembeck S (2005) Micro machining of cylindrical parts by electrical discharge grinding. Proc ISEM XIV

  23. Rahman M, Asad ABMA, Masaki T, Saleh T, Wong YS (2010) A Senthil Kumar. A multiprocess machine tool for compound machining. Int J Mach Tools Manuf 50:344–356

    Article  Google Scholar 

  24. Gil R, Sanchez JA, Ortega N, Plaza S, Izquierdo B, Pombo I (2012) Analysis of micro-pin manufacturing using inverse slab electrical discharge milling (ISEDM) process. J Key Eng Mater 496:247–356

    Article  Google Scholar 

  25. Soni JS, Chakraverti G (1994) Machining characteristics of titanium with rotary electro-discharge machining. Wear 171:51–58

    Article  Google Scholar 

  26. Waßenhoven K (1993) Funkenerosive Bearbeitung mit rotierender Stiftelektrode—Prozessanalyse und Verfahrensauslegung. Dissertation, RWTH Aachen

  27. Karthikeyan G, Ramkumar J, Dhamodaran S, Aravindan S (2010) Micro electric discharge milling process performance: an experimental investigation. Int J Mach Tool Manuf 50:718–727

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Engineering of Bilbao, University of the Basque Country, Alameda de Urquijo s/n, 48013, Bilbao, Spain

    R. Gil, J. A. Sánchez, N. Ortega & S. Plaza

  2. School of Technical Engineering of Eibar, University of the Basque Country, Avda. Otaola 26, 20600, Eibar, Spain

    B. Izquierdo

  3. School of Technical Engineering of Bilbao, University of the Basque Country, Plaza de la Casilla 3, 48012, Bilbao, Spain

    I. Pombo

Authors
  1. R. Gil
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. A. Sánchez
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. N. Ortega
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. S. Plaza
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. B. Izquierdo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. I. Pombo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to R. Gil.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Gil, R., Sánchez, J.A., Ortega, N. et al. High-aspect ratio micro-pin manufacturing using inverse slab electrical discharge milling (ISEDM) process. Int J Adv Manuf Technol 65, 1459–1469 (2013). https://doi.org/10.1007/s00170-012-4270-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-4270-5

Keywords

Search

Navigation