Arithmetic And Experimental Study Of Electrode Wear In Micro Ed-Milling

Micro electrical discharge machining (micro-EDM) is a very important method in the manufacture of micro three-dimensional structures. Scholars around the world attach much importance to it. The difficulty machining micro 3D structures is greatly increased due to the serious electrode wear in micro-EDM. This paper makes deep research on electrode compensation method for micro-EDM.First this paper studies the model of bottom surface profile in ED-milling, gives the formula of the profile trajectory, analyses the process of electrode bottom becoming a conical shape under fix-length compensation method combined rotating tool electrode, and researches the factors influencing the angle of electrode bottom.Then according to characteristics of conical bottom electrode, the mathematical model of fix-length compensation is established in electrical discharge milling (ED-milling), and the algorithm of compensation length is given. Then this paper obtains a precise way to measure the volume relative wear ratio based on the simulation and experiment. After milling using conical bottom electrode, there is serrated protrusion remained. So this paper proposes the fix-length compensation method approximate conical bottom electrode. Then a method that combines the uniform wear method and the fix-length compensation method is applied to cut away the final residues after two turns processing. The experimental results are basically consistent with the theoretical results. Finally, a tungsten microelectrode is made on-the-machine by using the Block electrode discharge grinding (BEDG). Through the experiments, it can be concluded that the compensation based on the conical bottom electrode is accurate and effective in micro ED-milling.