Abstract
Fabrication of micro-features by a Micro ED-milling (μED-milling) process requires machining of tool electrode and applying them in multi-pass trajectory. A real concern occurs when the tool has to be prepared before each pass and put into trajectory without disturbing the settings. This issue is attested to here by combining the process setup ofμED-milling, and Block Electric Discharge Grinding (Block EDG) without hindering the functionality of individual processes. But the Block EDG process itself suffers with a primary setback such as inability to predict the change in tool diameter during machining. The ability of Block EDG process is improved in this work by formulating regression model and tool quality loss characteristics evaluation. An empirical model for tool diameter as a function of energy and machining time is developed and validated to predict the diameter online at any point of machining. A data chart is prepared to show the typicalμ-tool defects during the fabrication process and possible remedies. Finally, the article concludes with employing the fabricated tools inμED-milling process to produce complex shapes through multiple pass machining technique.
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