Abstract
This paper provides an overall view of the current research in micro-electrical discharge machining (micro-EDM or µEDM) and looks into the present understanding of the material removing mechanism and the common approach for electrode material selection and its limitations. Based on experimental data, the authors present an analysis of different materials’ properties which have an influence on the electrodes’ wear ratio and energy distribution during the spark. The experiments performed in micro-EDM conditions reveal that properties such as electron work function and electrical resistivity strongly correlate with the discharge energy ratio. The electrode wear ratio, on the other hand, is strongly influenced by the atomic bonding energy and was found to be related to the tensile modulus. The proposed correlation functions characterized the data with a high determination coefficient exceeding 99%.
Highlights
Parameters Affecting Micro-EDM.Non-conventional processes such as electrochemical machining, electrical discharge machining, and laser machining are nowadays widely present in research as well as in industrial applications [1,2]
Recent efforts in the research and industrial applications of micro-EDM are of great interest as they promise to satisfy, to a great extent, the constant desire for miniaturization [7,8]
The size of the tool is much smaller. This leads to a greater energy density affecting the workpiece surface, and the assumption is that different phenomena of material removal in micro-EDM appear, which leads directly to material ablation rather than melting vaporization [23]
Summary
Non-conventional processes such as electrochemical machining, electrical discharge machining, and laser machining are nowadays widely present in research as well as in industrial applications [1,2]. They are used in the production of home appliances, personal well-being products [3], aviation components [4], medical instruments, and automotive parts [5,6]. Limitations concerning in-depth knowledge of non-conventional micro-machining and especially the lack of detailed theoretical understanding of the physical phenomena describing the material-removal process are major obstacles in achieving better control on micro and nano scales.
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