Hole Electrical Discharge Machining Using a High-Response and Multi-DOF Controlled Maglev Actuator (Effects of Direction, Amplitude and Frequency of Electrode Motion on Hole Machining Speed)

Abstract

This paper describes hole electrical discharge machining (EDM) using a cylindrical electrode driven by a high response and multi degrees of freedom (DOF) controlled magnetically-levitated (maglev) actuator. To avoid abnormal electrical discharge and achieve high speed hole EDM, several combinations of electrode motions such as high speed and high precision axial positioning to keep a gap voltage, jump motion, orbital motion and high frequency axial vibration of electrode (dither) for facilitating debris ejection were tested. Experimental results showed that the combination of the high speed positioning, jump and orbital motions of the electrode was effective for improving the speed of hole EDM. Finally, frequencies and diameters of the orbital motions were surveyed in order to improve the machining speed.