Development of a postprocessing approach for three-dimensional micro-electrical discharge machining milling and application in simultaneous micro-electrical discharge/electrochemical milling

Abstract

Micro-electrical discharge machining milling is a promising method to fabricate three-dimensional microshapes owing to its negligible cutting force and high-dimensional accuracy achievable. In order to machine intricate features, it requires the application of computer-aided manufacturing software to automatically generate the motion pattern for the electrode. Although most commercial computer-aided manufacturing systems cater for conventional milling, they cannot be directly applied for micro-electrical discharge machining milling due to the electrode wear issue and the existence of machining gap. This article presents these process-related issues and proposes an approach in customizing the conventional milling computer-aided manufacturing software for micro-electrical discharge machining milling of three-dimensional intricate shapes. The results show that it is feasible to utilize the current computer-aided manufacturing software to automatically generate tool paths for three-dimensional micro-electrical discharge machining milling by appropriately considering the tool wear and the inherent machining gap. In addition, further control parameters are also considered to achieve fine finish machining condition called simultaneous micro-electrical discharge/electrochemical milling. Different intricate three-dimensional microshapes are produced and evaluated to demonstrate the capability of this approach.