Study of Machining Characteristics of Micro EDM in Nitrogen Plasma Jet

Abstract

Micro electrical discharge machining (EDM) has been used to drill micro-holes and to generate micro-features for applications in automotive, aerospace and biomedical industries. The tool electrode wear ratio in micro-EDM usually is larger than that in conventional EDM process. It has been reported that the electrode wear ratio is almost zero in gas. However, its narrow discharge gap leads to frequent occurrence of abnormal discharges. In order to enlarge the discharge gap in micro-EDM, Nitrogen plasma jet (NPJ) has been used as the working media for micro-EDM in this study. NPJ is generated by using a needle-cylinder type corona discharge with an AC power supply in pure nitrogen gas. A RC-type pulse generator is used to realize micro electrical discharges in this investigation. It is expected that the electrons and ions in NPJ increase the electrical conductivity in the discharge gap. Thus, a large discharge gap can be obtained.To investigate the machining characteristics of micro-EDM in NPJ, series of experiments in NPJ, nitrogen jet (NJ) and deionized water (DIW) have been carried out. The discharge distance, machining time, electrode wear and surface roughness under different conditions have been recorded. The measured data has been analyzed together with the discharge signals. It was found that the discharge distance in NPJ is larger than that in NJ. The machining process in NPJ is much more stable than in NJ. The observed volumetric difference of electrode wear is very small, probably due to the small total material removal. The machining efficiency in DIW is the highest. However, the surface roughness in DIW is worse than that in NPJ.