Research On Micro-EDM Technology Of High Silicon Aluminum Alloy

As one of the most desired electronic packaging material, high silicon aluminumalloy has been used in the fields of aerospace and microwave circuits successfully.However, increased with silicon content, fragility of the material raises and itsmachinability decreases, especially in the process of micro beam and tiny hole machiningwhich is regularly used in electronic packaging piece, while hardly achieve demand withconventional machining which shows low success rate. Electrical discharge machining(EDM) owns tremendous advantage when machining fragile materials due to none macroapplied force. In addition, micro-EDM has irreplaceable place during machining microbeam, micro hole and micro three-dimensional structure. It is significant to have researchon micro-EDM manufacturing high silicon aluminum alloy, since it can help developapplication areas.Based on observing micro structure of high silicon aluminum alloy, analyzing andcomparing surfaces under different conditions-before and after EDM, this article sets upits simplified model. Furthermore, having detailed analysis about material remove in theprocess of micro-EDM.By means of single factor experiments, orthogonal experiments and analysis ofsurface morphology, having research on the influences of electrical parameters andmaterials of electrode on process time, electrode wear and surface morphology during theprocess of high silicon aluminum alloy machining micro-EDM milling. Under thefoundation of experiments, selecting suitable electrical parameters, combining withlayered milling uniform electrode wear and fix-length theories, this article manufacturesmicro three dimension structure successfully.By means of orthogonal experiments, having research on the influences of electricalparameters on process time and electrode wear during the process of high siliconaluminum alloy machining of micro hole. On the basis of the impacts of lift tool height,ultrasonic assist, cutting edge electrode on process results, acquired new method whichcould improve processing efficiency and reduce electrode wear.Through this research, micro-EDM can realize machining of micro beam, microhole and micro three dimension structure using high silicon aluminum alloy material.