Problems of the processing accuracy for electro-erosion and electro-chemical machining processes

Abstract

A large contradiction arises as regards the demands for a high working accuracy and a maximum produc-tivity when using the non-conventional manufacturing processes EDM and ECM. This problem will be further in-creased, if it concerns the machining of microstructures (μm range). The fundamental task is to achieve both a removal in a very small work gap (< 5 μm) and a fast regeneration of the work gap conditions. In the field of the Macromachin-ing the regeneration of the gap contamination can primarily occur via a well directed flushing. The Micromachining permits a sufficient flushing only to a limited degree, which requires that other ways have to be found in order to opti-mize the process. The most critical gap conditions are “the short-circuit effects“ for a process control of the Micro-machining. This paper will show the way under which the problems have to be analyzed in dielectric or electrolytic working mediums, and which solutions are possible.