Abstract
Micro-EDM milling is an effective machining process for three-dimension micro-cavity of high hardness materials. Fix-length compensation method is an efficient compensation method for cavity milling by improving single layer thickness. A truncated cone shaped end is formed under fix-length compensation method by using tubular electrode. This paper presents the compensation steps with tubular electrodes. According to the start hole drilling process, the geometrical model of the tubular electrode at the start point was established, and the compensation algorithm was given. Geometrical model for the ending part of the closed milling path was presented and the compensation algorithm was deduced. Two typical closed milling paths, square and circular paths, were manufactured based on the proposed compensation algorithms. Experimental results show that these two algorithms work well. The relative dimensional error is within 1.2%, and surface fluctuation is within 2.5μm.
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