Sequential Micro-EDM

  • MD. Rashef Mahbub
  • Asma Perveen
  • Muhammad P. JahanEmail author
Part of the Materials Forming, Machining and Tribology book series (MFMT)


In this chapter, different sequential conventional and non-conventional micromachining processes with micro-EDM have been discussed elaborately with their applications in modern-day research and industrial fields. The necessity and advantages of sequential micromachining processes and their difference from hybrid micromachining have been carefully identified. Micro-EDM combined with micro-grinding, micro-milling, micro-turning, micro-ECM, micro-drilling, laser micromachining, LIGA have been discussed with their advantages over respective single processes. The common issues that generally stand in the way of pulling out sequential processes successfully or hamper their accuracy have also been addressed. The chapter also suggests some initiatives to solve those issues. While wrapping up, the chapter emphasizes on the fact that how sequential micromachining, if properly implied, can solve a lot of problems that currently available single processes are dealing with and widen the vast possibility of micromachining of 3D complex structure with high level of accuracy.


Micro-EDM Sequential machining Micromachining Combined machining Micro-level accuracy Micro-tools 


  1. 1.
    Wada T, Masaki T, Davis D (2002) Development of micro grinding process using micro EDM trued diamond tools. In: ASPE proceeding, annual meeting, pp 16–19Google Scholar
  2. 2.
    Akça K, Chang T, Tekdemir İ, Fanuscu MI (2006) Biomechanical aspects of initial intraosseous stability and implant design: a quantitative micro-morphometric analysis. Clin Oral Implant Res 17(4):465–472CrossRefGoogle Scholar
  3. 3.
    Okandan M, Galambos P, Mani SS, Jakubczak JF (2001) Development of surface micromachining technologies for microfluidics and bioMEMS. SPIE Proc 4560:133–139CrossRefGoogle Scholar
  4. 4.
    Lim HS, Wong YS, Rahman M, Edwin Lee MK (2003) A study on the machining of high-aspect ratio micro-structures using micro-EDM. J Mater Process Technol 140(1–3):318–325CrossRefGoogle Scholar
  5. 5.
    Ho KH, Newman ST (2003) State of the art electrical discharge machining (EDM). Int J Mach Tools Manuf 43(13):1287–1300CrossRefGoogle Scholar
  6. 6.
    Liu HS, Yan BH, Chen CL, Huang FY (2006) Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining. Int J Mach Tools Manuf 46(1):80–87CrossRefGoogle Scholar
  7. 7.
    Liu HS, Yan BH, Chen CL, Huang FY (2006) Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining. Int J Mach Tools Manuf 46(1):80–87CrossRefGoogle Scholar
  8. 8.
    Wissmiller DL, Pfefferkorn FE (2009) Micro end mill tool temperature measurement and prediction. J Manuf Processes 11(1):45–53CrossRefGoogle Scholar
  9. 9.
    Cheng X, Wang Z, Nakamoto K, Yamazaki K (2010) Design and development of PCD micro straight edge end mills for micro/nano machining of hard and brittle materials. J Mech Sci Technol 24(11):2261–2268CrossRefGoogle Scholar
  10. 10.
    Kang IS, Kim JS, Seo YW (2008) Cutting force model considering tool edge geometry for micro end milling process. J Mech Sci Technol 22(2):293–299CrossRefGoogle Scholar
  11. 11.
    Cheng X, Yang X, Zheng G, Huang Y, Li L (2014) Fabrication accuracy analysis of micromilling tools with complicated geometries by wire EDM. J Mech Sci Technol 28(6):2329–2335CrossRefGoogle Scholar
  12. 12.
    Fonda P, Nakamoto K, Heidari A, Yang HA, Horsley DA, Lin L, Yamazaki K (2013) A study on the optimal fabrication method for micro-scale gyroscopes using a hybrid process consisting of electric discharge machining, chemical etching or micro-mechanical milling. CIRP Ann 62(1):183–186CrossRefGoogle Scholar
  13. 13.
    Zeng Z, Wang Y, Wang Z, Shan D, He X (2012) A study of micro-EDM and micro-ECM combined milling for 3D metallic micro-structures. Precis Eng 36(3):500–509CrossRefGoogle Scholar
  14. 14.
    He XL, Wang YK, Wang ZL, Zeng ZQ (2013) Micro-hole drilled by EDM-ECM combined processing. Key Eng Mater 562–565:52–56CrossRefGoogle Scholar
  15. 15.
    Wang MH, Zhu D (2009) Fabrication of multiple electrodes and their application for micro-holes array in ECM. Int J Adv Manuf Technol 41(1–2):42–47CrossRefGoogle Scholar
  16. 16.
    Pham DT, Dimov SS, Bigot S, Ivanov A, Popov K (2004) Micro-EDM—recent developments and research issues. J Mater Process Technol 149(1–3):50–57CrossRefGoogle Scholar
  17. 17.
    Weng FT, Her MG (2002) Study of the batch production of micro parts using the EDM process. Int J Adv Manuf Technol 19(4):266–270CrossRefGoogle Scholar
  18. 18.
    Dausinger F (2000) Precise drilling with short-pulsed lasers. High-power lasers in manufacturing. SPIE proceedings, vol 3888, pp 180–188Google Scholar
  19. 19.
    Meijer J, Du K, Gillner A, Hoffmann D, Kovalenko VS, Masuzawa T, Ostendorf A, Poprawe R, Schulz W (2002) Laser machining by short and ultrashort pulses, state of the art and new opportunities in the age of the photons. CIRP Ann 51(2):531–550CrossRefGoogle Scholar
  20. 20.
    Li L, Diver C, Atkinson J, Giedl-Wagner R, Helml HJ (2006) Sequential laser and EDM micro-drilling for next generation fuel injection nozzle manufacture. CIRP Ann Manuf Technol 55(1):179–182CrossRefGoogle Scholar
  21. 21.
    Kuo CL, Huang JD, Liang HY (2003) Fabrication of 3D metal microstructures using a hybrid process of micro-EDM and laser assembly. Int J Adv Manuf Technol 21(10–11):796–800CrossRefGoogle Scholar
  22. 22.
    Guckel H, Skrobis KJ, Christenson TR, Klein J (1994) Micromechanics for actuators via deep X-ray lithography. Electron-beam, X-ray, and ion-beam submicrometer lithographies for manufacturing IV. SPIE Proc 2194:2–11CrossRefGoogle Scholar
  23. 23.
    Masaki T, Kawata K, Masuzawa T (1990) Micro electro-discharge machining and its applications. In: IEEE proceedings on micro electro mechanical systems, an investigation of micro structures, sensors, actuators, machines and robots, pp 21–26Google Scholar
  24. 24.
    Takahata K, Aoki S, Sato T (1997) Fine surface finishing method for 3-dimensional micro structures. In: Proceedings of ninth international workshop on micro electromechanical systems, pp 291–296Google Scholar
  25. 25.
    Takahata K, Shibaike N, Guckel H (2000) High-aspect-ratio WC-Co microstructure produced by the combination of LIGA and micro-EDM. Microsyst Technol 6(5):175–178CrossRefGoogle Scholar
  26. 26.
    Tseng SC, Chen YC, Kuo CL, Shew BY (2005) A study of integration of LIGA and M-EDM technology on the microinjection molding of ink-jet printers’ nozzle plates. Microsyst Technol 12(1–2):116–119CrossRefGoogle Scholar
  27. 27.
    Asad ABMA, Masaki T, Rahman M, Lim HS, Wong YS (2007) Tool-based micro-machining. J Mater Process Technol 192–193:204–211CrossRefGoogle Scholar
  28. 28.
    Hung JC, Yan BH, Liu HS, Chow HM (2006) Micro-hole machining using micro-EDM combined with electropolishing. J Micromech Microeng 16(8):1480–1486CrossRefGoogle Scholar
  29. 29.
    Ramasawmy H, Blunt L (2002) 3D surface characterisation of electropolished EDMed surface and quantitative assessment of process variables using Taguchi Methodology. Int J Mach Tools Manuf 42(10):1129–1133CrossRefGoogle Scholar
  30. 30.
    Hocheng H, Pa PS (1999) Electropolishing and electrobrightening of holes using different feeding electrodes. J Mater Process Technol 89:440–446CrossRefGoogle Scholar
  31. 31.
    Sato T (1994) Nontraditional machining. Yokendo, TokyoGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  • MD. Rashef Mahbub
    • 1
  • Asma Perveen
    • 2
  • Muhammad P. Jahan
    • 1
    Email author
  1. 1.Department of Mechanical and Manufacturing EngineeringMiami UniversityOxfordUSA
  2. 2.Department of Mechanical EngineeringNazarbayev UniversityAstanaKazakhstan

Personalised recommendations