Skip to main content
SpringerLink
Log in

Influence of alternating side gap on micro-hole machining performances in micro-EDM

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

Abstract

In the machining of micro-hole by micro-EDM, the narrow and uniform side gap leads to the difficulty in removing discharge debris from the working area, which causes frequent occurrence of abnormal discharges such as short circuit. In this study, a three-dimensional model with alternating side gap was proposed, based on which the flow field and movement of discharge debris in working gap were analyzed. Simulation results showed that the alternating side gap changed the flow field pattern in bottom gap, and the flow velocities both in bottom gap and side gap were increased as the enlargement of eccentric radius. In addition, when the alternating side gap was adopted, the concentration of debris particles in the bottom gap was dramatically decreased due to the improvement of flow field in the working gap, and the percentage of escaped debris particles was increased. Verifying experiments were carried out and the influences of alternating side gap on the micro-hole machining performances were addressed, which showed that both the material removal rate and aspect ratio of micro-hole were improved as the eccentric radius increases. Nevertheless, the eccentric radius still needs to be determined reasonably in consideration of the wear of electrode.

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. Li CJ, Li Y, Tong H, Zhao L, Kong QC, Wang ZQ (2016) An EDM pulse power generator and its feasible experiments for drilling film cooling holes. Int J Adv Manuf Technol 87(5–8):1813–1821

    Article  Google Scholar 

  2. Liu HS, Yan BH, Huang FY, Qiu KH (2005) A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications. J Mater Process Technol 169(3):418–426

    Article  Google Scholar 

  3. Masuzawa T (2000) State of the art of micro machining. CIRP Ann-Manuf Technol 49(2):473–488

    Article  Google Scholar 

  4. Li ZY, Wei XT, Sun JJ, Zang CW, Fu CH, Guo YB (2016) Process capability and effect size of vacuum extraction shaped tube electrolytic drilling of Inconel alloy for high-performance cooling hole. Int J Adv Manuf Technol 85(9–12):2557–2566

    Article  Google Scholar 

  5. Jahan MP, Wong YS, 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. J Mater Process Technol 209(4):1706–1716

    Article  Google Scholar 

  6. D’Urso G, Maccarini G, Ravasio C (2016) Influence of electrode material in micro-EDM drilling of stainless steel and tungsten carbide. Int J Adv Manuf Technol 85(9–12):2013–2025

    Article  Google Scholar 

  7. Ay M, Çaydaş U, Hasçalık A (2013) Optimization of micro-EDM drilling of Inconel 718 superalloy. Int J Adv Manuf Technol 66(5–8):1015–1023

    Article  Google Scholar 

  8. Abbas NM, Solomon DG, Bahari MF (2007) A review on current research trends in electrical discharge machining (EDM). Int J Mach Tools Manuf 47(7):1214–1228

    Article  Google Scholar 

  9. Moses MD, Jahan MP (2015) Micro-EDM machinability of difficult-to-cut Ti-6Al-4V against soft brass. Int J Adv Manuf Technol 81(5–8):1345–1361

    Article  Google Scholar 

  10. Tiwary A, Pradhan B, Bhattacharyya B (2015) Study on the influence of micro-EDM process parameters during machining of Ti-6Al-4V superalloy. Int J Adv Manuf Technol 76:151–160

    Article  Google Scholar 

  11. Fu XZ, Zhang Y, Zhang QH, Zhang JH (2013) Research on piezoelectric self-adaptive micro-EDM. Procedia CIRP 6:303–308

    Article  Google Scholar 

  12. Yahagi Y, Koyano T, Kunieda M, Yang XD (2012) Micro drilling EDM with high rotation speed of tool electrode using the electrostatic induction feeding method. Procedia CIRP 1:162–165

    Article  Google Scholar 

  13. Liao YS, Liang HW (2016) Study of vibration assisted inclined feed micro-EDM drilling. Procedia CIRP 42:552–556

    Article  Google Scholar 

  14. Zhao WS, Wang ZL, Di SC, Chi GX, Wei HY (2002) Ultrasonic and electric discharge machining to deep and small hole on titanium alloy. J Mater Process Technol 120(1):101–106

    Google Scholar 

  15. Ichikawa T, Natsu W (2013) Realization of micro-EDM under ultra-small discharge energy by applying ultrasonic vibration to machining fluid. Procedia CIRP 6:326–331

    Article  Google Scholar 

  16. Yu ZY, Zhang Y, Li J, Luan J, Zhao F, Guo D (2009) High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM. CIRP Ann-Manuf Technol 58(1):213–216

    Article  Google Scholar 

  17. Yu ZY, Rajurkar KP, Shen H (2002) High aspect ratio and complex shaped blind micro holes by micro EDM. CIRP Ann-Manuf Technol 51(1):359–362

    Article  Google Scholar 

  18. Plaza S, Sanchez JA, Perez E, Gil R, Lzquierdo B, Ortega N, Pombo I (2014) Experimental study on micro EDM-drilling of Ti6Al4V using helical electrode. Precis Eng 38(4):821–827

    Article  Google Scholar 

  19. Hung JC, Lin JK, Yan BH, Liu HS, Ho PH (2006) Using a helical micro-tool in micro-EDM combined with ultrasonic vibration for micro-hole machining. J Micromech Microeng 16(12):2705

    Article  Google Scholar 

  20. Mastud SA, Kothari NS, Singh RK, Joshi SS (2015) Modeling debris motion in vibration assisted reverse micro electrical discharge machining process (R-MEDM). J Microelectromech S 24(3):661–676

    Article  Google Scholar 

  21. Cetin S, Okada A, UNO Y (2004) Effect of debris distribution on wall concavity in deep-hole EDM. JSME Int J C 47(2):553–559

    Article  Google Scholar 

  22. Wang J, Han FZ (2014) Simulation model of debris and bubble movement in consecutive-pulse discharge of electrical discharge machining. Int J Mach Tools Manuf 77:56–65

    Article  Google Scholar 

  23. Okada A, Uno Y, Onoda S, Habib S (2009) Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf. CIRP Ann-Manuf Technol 58(1):209–212

    Article  Google Scholar 

  24. Wu MH, Wang YG, Zhao FL (2009) Wear mechanism and preventive measure of electrode in micro-EDM. Appl Mech Mater 16:540–543

    Article  Google Scholar 

  25. Wang YG, Zhao FL, Wang J (2009) Wear-resist electrodes for micro-EDM. Chinese J Aeronaut 22(3):339–342

    Article  MathSciNet  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, Heilongjiang, 150001, China

    Zhengkai Li & Jicheng Bai

Authors
  1. Zhengkai Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jicheng Bai
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jicheng Bai.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, Z., Bai, J. Influence of alternating side gap on micro-hole machining performances in micro-EDM. Int J Adv Manuf Technol 94, 979–989 (2018). https://doi.org/10.1007/s00170-017-0959-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0959-9

Keywords

Search

Navigation