Abstract
To further study the discharge characteristics and machining mechanism of micro-electrical discharge machining (micro-EDM), the variation trends of the discharge energy and discharge crater size with actual discharge duration are discussed based on single-pulse experiments. The polarity effect of micro-EDM was analyzed according to the motion characteristics of electrons and ions in the discharge plasma channel. The results show that the discharge current and voltage of micro-EDM were independent of the discharge width and open-circuit voltage. The energy utilization rate of the short-pulse discharge was relatively high, and the energy utilization rate decreased gradually as the discharge duration increased. Even if the mass of the positive ion was much larger than that of the electron, the kinetic energy of the positive ion was still less than that of the electron when bombarding the surface of the electrode. The acceleration and speed of electrons were very high, and the number of times that electrons bombarded the surface of positive electrode was more than 600 times that of positive ions bombarding the surface of the negative electrode during the same time.
Highlights
With the increasing market demand for miniaturization and the precision of products, micro-processing technology has become one of the important indicators to measure a country’s scientific and technological strength [1–3]
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The variation trends of discharge energy, radius, depth, and volume of discharge crater with discharge duration were discussed based on the experimental results of a single-pulse discharge of micro-EDM
Summary
With the increasing market demand for miniaturization and the precision of products, micro-processing technology has become one of the important indicators to measure a country’s scientific and technological strength [1–3]. Micro-electrical discharge machining (micro-EDM) has become one of the most popular microfabrication technologies due to the advantage of machining electrically conductive materials without direct contact [4–6]. Micro-EDM has been has attracted great attention from researchers and has been widely used in the micro-machining field [7–9]. The micro-EDM performance is affected by various conditions, such as processing parameters, and the dielectric and electrode characteristics, which makes it extremely difficult to explain the machining mechanism of micro-EDM. The instability of the discharge state, the extremely high discharge frequency, the very small discharge gap, and the very small discharge energy lead to the large randomness of the shape and size of the discharge crater in micro-EDM [13]. There are two main reasons why it is difficult to study the machining mechanism of micro-scale EDM: one is the randomness and complexity of the discharge process; the other is the lack of sufficient understanding. Idnisacdhdairtigoen,cbhaasnendeol,ntthhee mosocvilelamtieontchoaf realcetcetrriostnicssaonfdthieodnisscahtarthge cdhiasnchnaerl,gtehepmoionvt ewmaesntthoef oerleectitcroanllsy aanndaliyoznesda,tatnhde tdhiescphoalragreitypoeifnfetcwt aosf tmhiecorroe-tEicDaMllywanaaslaynzaeldy,zaenddatnhde ipsodlaisrcituysseeffde.ct of micro-EDM was analyzed and is discussed
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