Abstract
Nowadays, micro-machining techniques are commonly used in several industrial fields, such as automotive, aerospace and medical. Different technologies are available, and the choice must be made considering many factors, such as the type of machining, the number of lots and the required accuracy specifications in terms of geometrical tolerances and surface finish. Lasers and electric discharge machining (EDM) are widely used to produce micro-components and are similarly unconventional thermal technologies. In general, a laser is particularly appreciated by the industry for the excellent machining speeds and for the possibility to machine essentially any type of materials. EDM, on the other hand, has a poor material removal rate (MRR) but can produce microparts on only electrically conductive workpieces, reaching high geometrical accuracy and realizing steep walls. The most common micro-application for both the technologies is drilling but they can make also milling operations. In this work, a comparison of femto-laser and EDM technologies was made focusing on micro-milling. Two features were selected to make the comparison: micro-channels and micro-pillars. The depth was varied on two levels for both features. As workpiece material, aluminum, stainless steel and titanium alloy were tested. Data regarding the process performance and the geometrical characteristics of the features were analyzed. The results obtained with the two technologies were compared. This work improves the knowledge of the micro-manufacturing processes and can help in the characterization of their capabilities.
Highlights
As4.4.already discussed in theofofIntroduction, actualfor geometry achievable on the the femtosecond laser the technology: (b) femtosecondhas laseraand and theEDM
With a fixed workpiece material, the effect of the depth of the pillars is clear: the electrode wear is proportional to the machine depth, as the material removal rate (MRR) is almost constant; increasing the depth, the material removal occurs with the same feed, and the top and bottom dimensions of the pillars are similar; the taper rate is around the double at a depth of 50 μm than 100 μm
It can be noted that when stainless steel and titanium is the difference the taperofrate two technologies is not high, it is useful machined, the of difference the between taper ratethe between the two technologies is but not high, but it to remarktothat, in these cases, electric discharge machining (EDM) present a loweradepth to those is useful remark that, in thesechannels cases, channels
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Due to the inherent configuration of the laser milling process, the actual geometry achievable on the workpiece will inevitably feature a positive taper angle This side effect can be partially tuned by applying special techniques and pieces of equipment (such as static beam inclination or dynamic precession mode ablation) [13]. Duespark to thedischarges inherent configuration of the tool laser(electrode) milling process, actual geometry to machine complex micro-parts of only conductive materials that traditional processes achievable on the workpiece will inevitably feature a positive taper angle. This side effect are be unable to create [14]. The production field as a function of the characteristics of the microcomponents that have to be produced
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