Abstract
ABSTRACTIn the micro-electro discharge machining (micro-EDM) process the machined surface consists of tiny overlapping craters. The shape of the crater has significant influence on the characteristics of the machined surface. However, existing models on crater shapes generally do not represent characteristic features of the craters, such as the bulging rim around the crater and the asymmetrical bowl-shape. In this study, experiments were conducted to examine three-dimensional (3D) geometrical features of craters in micro-EDM. Based on the experimental data, a geometric model of craters is proposed to better represent and understand the 3D shapes of single craters. A uniform model and a more realistic nonuniform model of crater geometry are developed, taking into account the bulging rim and the asymmetrical shape in craters. Furthermore, a method of constructing overlapping craters using nonuniform models of single craters is proposed and presented. This method is capable of representing major geometrical features of actual crater clusters.
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