Abstract
The objective of this research is to achieve high-speed electrical discharge machining (EDM) of small holes using a high-speed, high-precision, 3-DOF controlled, magnetic/piezoelectric hybrid drive actuator. In this paper, the proposed actuator was attached to the conventional electrical discharge machine, and the increase in the machining speed using the actuator was experimentally confirmed. The relationships between the machining speed, the amplitude and the frequency of the electrode vibration were discussed. Experimental results show that the use of the proposed actuator can speedily adjust the distance between the electrode and the workpiece, and the machining speed was increased by 138% compared with the conventional EDM. Moreover, the machining speed using the actuator also was increased as the changes of the amplitude and the frequency of the electrode vibration, and it was increased by 76% compared to without the electrode vibration.
Highlights
Electrical discharge machining (EDM) is a nonconventional material removal processes based on the thermo-electric energy created between an electrically conductive workpiece and an electrode submerged in a machining fluid
In order to evaluate the effectiveness of the proposed actuator for improvement of EDM machining speed, straight holes were machined in the thrust direction
The machining speed using the actuator was increased as the changes of the amplitude and the frequency of the electrode vibration, and it was increased by 76% compared to without the electrode vibration, and 315% compared to conventional EDM
Summary
Electrical discharge machining (EDM) is a nonconventional material removal processes based on the thermo-electric energy created between an electrically conductive workpiece and an electrode submerged in a machining fluid. To obtain a stable electrical discharge, the electrode needs to be speedily re-positioned in order to maintain a suitable distance from the workpiece, and the debris around the electrode due to EDM has to be removed immediately. The actuator primarily consists of a thrust magnetic bearing, a pair of elastic hinges, and an electrode vibration mechanism in the radial directions. The thrust magnetic bearing with a positioning stroke of a few millimeters can realize speedy position of the electrode in order to maintain a suitable distance from the workpiece, and the fast jump theelectrode to introduce fresh machining fluid into the hole and wash away debris.
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