Abstract
Micro-electro-discharge machining (μEDM) plays a significant role in miniaturization. Complex electrode manufacturing and a high wear ratio are bottlenecks for μEDM and seriously restrict the manufacturing of microcomponents. To solve the electrode problems in traditional EDM, a µEDM method using liquid metal as the machining electrode was developed. Briefly, a liquid-metal tip was suspended at the end of a capillary nozzle and used as the discharge electrode for sparking the workpiece and removing workpiece material. During discharge, the liquid electrode was continuously supplied to the nozzle to eliminate the effects of liquid consumption on the erosion process. The forming process of a liquid-metal electrode tip and the influence of an applied external pressure and electric field on the electrode shape were theoretically analyzed. The effects of external pressure and electric field on the material removal rate (MRR), liquid-metal consumption rate (LMCR), and groove width were experimentally analyzed. Simulation results showed that the external pressure and electric field had a large influence on the electrode shape. Experimental results showed that the geometry and shape of the liquid-metal electrode could be controlled and constrained; furthermore, liquid consumption could be well compensated, which was very suitable for µEDM.
Highlights
Micro-electro-discharge machining is a powerful micromachining technique with various advantages resulting from it being a noncontact and thermal process; μEDM is applicable to any electrically conductive material regardless of the mechanical properties of the material
The shape of the electrode, which is used in liquid-electrode μEDM processing for the purpose of resolving the problems related to electrode wear in traditional μEDM, was analyzed and simulated
The external pressure had a significant impact on the tip shape of the liquid electrode and its compensation
Summary
Micro-electro-discharge machining (μEDM) is a powerful micromachining technique with various advantages resulting from it being a noncontact and thermal process; μEDM is applicable to any electrically conductive material regardless of the mechanical properties of the material. In the case without an electric field force, asl5shown, the tip shape of the liquid-metal electrode will form a spherical shape due to surface tension, as discussed before. Equation (12) shows the electric field force of the entire liquid-metal convex sphere This is to analyze the entire spherical surface as a whole. To analyze the influence of the electric field force on the tip shape of the liquid-metal electrode, it is necessary to divide the spherical surface of ( ) + R (cosα −1) − d1 cos(α / 2) 16R2 + d12. To analyze the influence of the electric field force on the tip shape of the liquid-metal electrode, it is necessary to divide the spherical surface of tthhee lliiqquuiidd--mmeettaallttiipp iinnttoo aann iinnffiinniittee nnuummbbeerr ooff mmiiccrrooeelleemmeennttss ttoo aannaallyyzzee tthhee ffoorrccee ssiittuuaattiioonn ooff eeaacchh mmiiccrrooeelleemmeenntt. Simulation results at different extra pressures. (a) 0.1 atm. (b) 0.8 atm. (c) 1.2 atm. (d) 1.4 atm. (e) 2 atm
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