Abstract
Electro Discharge Machining is no longer taken as a “force free” process. Studies are being completed in order to understand how these forces are being exerted on the electrodes and how they might affect the processing of highly precise or high aspect ratio geometries. This paper studies process forces on macro Sinking-EDM with the use of two highly precise piezoelectric axial force sensors which measure single discharge forces simultaneously at the tool and workpiece sides. At the same time, the vibration amplitude and frequency of tool electrodes are measured, along with the analysis of high-speed-camera photographs showing a chronological sequence of gas bubble formation in terms of their dilatation and collapse, allowing a more detailed view into the process. The understanding of the dynamic trends of these process forces allows drawing conclusions about the generation of the pressure field along the working gap and its influence on tool electrode vibration which can decrease the final desired precision of the manufactured workpiece.
Similar content being viewed by others
References
Klocke F, Thomaidis D, Garzón M, Veselovac D, Klink A (2007) Force measurements in the micro spark erosion with various electrode materials, polarities and working media. In: Proceedings of the 15th international symposium on electro machining, pp 263–268
Tamura T, Kobayashi Y (2004) Measurement of impulsive forces and crater formation in impulse discharge. J Mat Proc Technol 149:212–221
Tohi M, Komatsu T, Kunieda M (2002) Measurement of process reaction force in EDM using Hopkinson bar method. JSPE 68:822–826
Kunieda M, Tohi M, Ohsako Y (2003) Reaction forces observed in pulse discharges of EDM. Int J Elect Mach 8:51–56
Klocke F, Garzón M (2009) Implications of forces observed during sinking-EDM on precision manufacturing. In: Proceedings of the Euspen international conference—San Sebastian, vol 2, pp 102–105
Uhlmann E, Piltz S, Oberschmidt D (2008) Machining of micro rotational parts by wire electrical discharge grinding, production engineering, german academic society for production engineering (WGP), vol 2, 3rd edn. pp 227–233
Thomaidis D (2007) Pulveradditivierte Dielektrika in der Mikrosenkerosion. Dissertation RWTH Aachen, p 70–75
Kundu P (1990) Fluid mechanics. Academic Press, Inc., San Diego, CA, pp 141–183
Klocke F, Dieckmann J, Garzón M (2010) Investigation on dynamic gas bubble formation by using a high-speed-camera system. In: Proceedings of the 16th international symposium on electro machining, p 145–148
Weinert K, Surmann T, Enk D, Webber, O (2007) The effect of run out on the milling tool vibration and surface quality, production engineering, german academic society for production engineering (WGP), vol 1. pp 265–270
Takehuchi H, Kunieda M (2007) Effects of volume fraction of bubbles in discharge gap on machining phenomena of EDM. In: Proceedings of the 15th international symposium on electromachining, pp 63–68
Acknowledgments
This work has been partially funded by the German Research Association DFG within the project KL500/63-1 “Grundlagenorientierte Optimierung der Mikrosenkerosion”.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Klocke, F., Garzón, M., Dieckmann, J. et al. Process force analysis on sinking-EDM electrodes for the precision manufacturing. Prod. Eng. Res. Devel. 5, 183–190 (2011). https://doi.org/10.1007/s11740-010-0292-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11740-010-0292-8