Electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult-to-machine by conventional machining processes. The non-contact machining technique has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests. In recent years, EDM researchers have explored a number of ways to improve the sparking efficiency including some unique experimental concepts that depart from the EDM traditional sparking phenomenon. Despite a range of different approaches, this new research shares the same objectives of achieving more efficient metal removal coupled with a reduction in tool wear and improved surface quality. This paper reviews the research work carried out from the inception to the development of die-sinking EDM within the past decade. It reports on the EDM research relating to improving performance measures, optimising the process variables, monitoring and control the sparking process, simplifying the electrode design and manufacture. A range of EDM applications are highlighted together with the development of hybrid machining processes. The final part of the paper discusses these developments and outlines the trends for future EDM research.

http://zclient.persiangig.com/ScienceDirect/M02.pdf

State of the art electrical discharge machining (EDM)

In many areas of industry, it is desirable to create geometric models of existing objects for which no such model is available. This paper reviews the process of reverse engineering of shapes. After identifying the purpose of reverse engineering and the main application areas, the most important algorithmic steps are outlined and various reconstruction strategies are presented. Pros and cons of various data acquisition techniques are described with related problems of boundary representation model construction. Specific issues addressed include characterization of geometric models and related surface representations, segmentation and surface fitting for simple and free-form shapes, multiple view combination and creating consistent and accurate B-rep models. The limitations of currently known solutions are also described, and we point out areas in which further work is required before reverse engineering of shape becomes a practical, widely-available engineering tool.

Reverse engineering of geometric models—an introduction

Advancing EDM through fundamental insight into the process

https://escholarship.org/content/qt8rf718jm/qt8rf718jm.pdf?t=krnesf

Recent Advances in Mechanical Micromachining

The miniaturization of machine components is perceived by many as a requirement for the future technological development of a broad spectrum of products. Miniature components can provide smaller footprints, lower power consumption and higher heat transfer, since their surface-to-volume ratio is very high. To create these components, micro-meso-scale fabrication using miniaturized mechanical material removal processes has a unique advantage in creating 3D components using a variety of engineering materials. The motivation for micro-mechanical cutting stems from the translation of the knowledge obtained from the macro-machining domain to the micro-domain. However, there are challenges and limitations to micro-machining, and simple scaling cannot be used to model the phenomena of micro-machining operations. This paper surveys the current efforts in mechanical micro-machining research and applications, especially for micro-milling operations, and suggests areas from macro-machining that should be examined and researched for application to the improvement of micro-machining processes.

Toshio Sata

Papers

Brittle-Ductile Transition Phenomena in Microindentation and Micromachining

Some Considerations to Machining Characteristics of Insulating Ceramics-Towards Practical Use in Industry-

Development of a 5-Axis Control Ultraprecision Milling Machine for Micromachining Based on Non-Friction Servomechanisms

A New Process of Additive and Removal Machining by EDM with a Thin Electrode

On a Possible Mechanism of Shear Deformation in Nanoscale Cutting