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Micro-electrical Discharge Milling Operation

  • Mahavir Singh
  • Vijay Kumar Jain
  • Janakarajan RamkumarEmail author
Chapter
Part of the Materials Forming, Machining and Tribology book series (MFMT)

Abstract

This chapter introduces a novel variant of electric discharge machining (EDM) process entitled to electrical discharge milling (ED-Milling) operation. Although the mechanism of material removal is essentially identical to that of conventional EDM process, the intricacies arise predominantly pertaining to the multiple zones involved simultaneously during the sparking phenomenon. Unlike the Ram/die-sinking EDM or ED-Drilling operations comprising merely unidirectional control of the tool electrode, the ED-Milling operation is characterized by the synchronized movement of the tool in multiple axes (generally x-, y-, and z-axis) besides the high-speed rotation about its axis. This controlled motion of the tool electrode governed by the programmed instructions similar to the computerized numerical control (CNC) of conventional milling operation makes it a prospective contender especially for fabrication of 3D micro/macro-profiles. Incorporating a comparatively simpler cylindrical or in exceptional instances rectangular/square cross-sectional tool electrode to generate a complex three-dimensional feature is the distinctive capability of this operation. The chapter comprises the basic introduction to EDM process in conjunction with ED-Milling operation, different techniques of micro-tool production as well as micro-fabrication, suitability of ED-Milling operation for a variety of sophisticated areas, analysis of tool wear and the possible applications areas of the process.

Keywords

Micro-channels Tool wear Computer numerical control Taper angle Micro-tools Debris 

Nomenclature

C

Capacitance of the capacitor (µF)

Vd

Discharge voltage (V)

I

Machining current (A)

t

Pulse on time (µs or ns)

Δx

Average machining depth of a single layer (µm or mm)

Δd

Compensated depth of the tool considering the longitudinal wear (µm or mm)

Ae

Cross-sectional area of the tool in the x-y plane (µm2 or mm2)

Aw

Cross-sectional area of the workpiece in the x-y plane (µm2 or mm2)

α

Wear ratio (ratio of the volume of tool material removed to the volume of workpiece removed)

le

Compensation accuracy (µm or mm)

L

Machining length (µm or mm)

nJ

Nano-Joule

3D

Three-dimensional

AMPs

Advanced machining processes

IEG

Inter-electrode gap

EDG

Electric discharge grinding

AJM

Abrasive jet machining

WJM

Water jet machining

AWJM

Abrasive water jet machining

LIGA

Lithographie, Galvanoformung, Abformung

HAZ

Heat-affected zone

µ

Micro

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Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  • Mahavir Singh
    • 1
  • Vijay Kumar Jain
    • 1
    • 2
  • Janakarajan Ramkumar
    • 1
    Email author
  1. 1.Department of Mechanical EngineeringIndian Institute of Technology KanpurKanpurIndia
  2. 2.Department of Mechanical EngineeringMaulana Azad National Institute of Technology BhopalBhopalIndia

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