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Journal ArticleDOI

A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications

01 Dec 2005-Journal of Materials Processing Technology (Elsevier)-Vol. 169, Iss: 3, pp 418-426
TL;DR: In this article, the feasibility of fabricating micro-holes in the high nickel alloy using micro-electro-discharge machining (micro-EDM) was investigated.
About: This article is published in Journal of Materials Processing Technology.The article was published on 2005-12-01. It has received 123 citations till now. The article focuses on the topics: Machining & Cutting tool.
Citations
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Journal ArticleDOI
TL;DR: In this paper, the authors report the worldwide technical developments and state-of-the-art of electro-physical and chemical micromachining processes and issues related to the supporting technologies such as standardization, metrology and equipment design are briefly assessed.

358 citations

Journal ArticleDOI
TL;DR: In this paper, the influence of EDM parameters on material removal rate, electrode wear, machining time and micro-hole quality when machining Ti6Al4V is studied.
Abstract: There is a growing interest in the machining of micro-holes with high aspect-ratio in difficult-to-machine alloys for the aerospace industry. Processes based on electro discharge machining (EDM) and developed for the manufacture of both micro-electrode and micro-hole are actually used, but most of them involve micro-EDM machines. In this work, the influence of EDM parameters on material removal rate, electrode wear, machining time and micro-hole quality when machining Ti6Al4V is studied. Due to an inefficient removal of debris when increasing hole depth, a new strategy based on the use of helical-shaped electrodes has been proposed. The influence of helix angle and flute depth with respect to process performance has been addressed. Main results include 37% reduction in machining times (hole diameter 800 μm) when using electrode helix angle of 45° and flute-depth of 50 μm, and an additional 19% with flute-depth of 150 μm. Holes of 661 μm diameter and as much as 6.81 mm depth, which yields in aspect ratio of 10:1, have successfully been machined in Ti6Al4V.

130 citations


Cites background or methods from "A study on the characterization of ..."

  • ...In [9], the EDM of microoles of different shapes on difficult-to-machine high nickel alloy trade mark Hymu80) is described....

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  • ...From the ideas pointed out in [9], a new helical-grooved high aspect-ratio electrode has been manufactured using the ISEDM process....

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  • ...As explained above, in [13], the helical tool geometry previusly presented in [9] is applied in combination with ultrasonic achining for micro-hole machining in the same high nickel alloy....

    [...]

01 Jan 2010
TL;DR: In this paper, the state-of-the-art technology of high-performance machining of advanced materials using Die Sinking EDM, WEDM, Micro-EDM and RDE EDM are reviewed.
Abstract: Present manufacturing industries are facing challenges from these advanced materials viz. super alloys, ceramics, and composites, that are hard and difficult to machine, requiring high precision, surface quality which increases machining cost. To meet these challenges, non-conventional machining processes are being employed to achieve higher metal removal rate, better surface finish and greater dimensional accuracy, with less tool wear. Electric Discharge Machining (EDM), a non-conventional process, has a wide applications in automotive, defense, aerospace and micro systems industries plays an excellent role in the development of least cost products with more reliable quality assurance. Die sinking EDM, Rotating pin electrode (RPE), Wire electrical discharge machining (WEDM), Micro- EDM, Dry EDM, Rotary disk electrode electrical discharge machining (RDE-EDM) are some of the variants methods of EDM. The present paper review the state of the art technology of high-performance machining of advanced materials using Die Sinking EDM, WEDM, Micro-EDM, Dry EDM AND RDE-EDM. The review relies on notable academic publications and recent conference proceedings.

113 citations

Journal ArticleDOI
TL;DR: In this article, the feasibility of machining deep microholes in two difficult-to-cut materials: cemented carbide (WC-Co) and austenitic stainless steel (SUS 304) using the micro-EDM drilling was investigated.
Abstract: Microelectro-discharge machining (micro-EDM) has become a widely accepted non-traditional material removal process for machining difficult-to-cut but conductive materials effectively and economically. The present study aims to investigate the feasibility of machining deep microholes in two difficult-to-cut materials: cemented carbide (WC-Co) and austenitic stainless steel (SUS 304) using the micro-EDM drilling. The effect of discharge energy and electro-thermal material properties on the performance of the two work materials during the micro-EDM drilling has also been investigated. The micro-EDM drilling performance of two materials has been assessed based on the quality and accuracy of the produced microholes, machining stability, material removal rate (MRR), and electrode wear ratio. The results show that deep-hole micro-EDM drilling is technically more feasible in WC-Co as it offers microholes with smooth and burr-free surfaces at the rim in addition to improved circularity and lower overcut than those provided by SUS 304. Moreover, WC-Co exhibits better machinability during the deep-hole micro-EDM drilling, providing relatively higher MRR and stable machining.

91 citations


Cites background from "A study on the characterization of ..."

  • ...This phenomenon causes the entrance of the microholes to be larger [ 30 ]....

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Journal ArticleDOI
TL;DR: In this paper, a hybrid machining process which combines laser and micro-EDM processes for drilling microholes in advanced engineering materials such as Nickel-Titanium (Ni-Ti)-based shape memory alloy was proposed.
Abstract: Micro-electrical discharge machining (EDM) is a slow process as compared to laser machining, on the contrary laser machining lacks good surface quality. To overcome the drawbacks of both these processes, this paper suggests a hybrid machining process which combines laser and micro-EDM processes for drilling microholes in advanced engineering materials such as Nickel–Titanium (Ni–Ti)-based shape memory alloy. To achieve the objective of the suggested hybrid process, pilot holes are drilled with laser machine and rimmed out by micro-EDM drilling. The suggested process requires investigation of various combinations of micro-EDM drilling process conditions to obtain optimum machining parameters for the hybrid process. It has been found that the proposed hybrid machining process resulted in 50–65% reduction in machining time without affecting the quality of microholes as compared to the standard micro-EDM process.

85 citations


Cites methods from "A study on the characterization of ..."

  • ...Micro-EDM has been used for fabricating microholes on nickel alloy for MEMS applications [10]....

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References
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Journal ArticleDOI
TL;DR: In this paper, a new method, WEDG (wire electro-discharge grinding), for EDM'ing very thin rods is proposed, where travelling wire is used as the tool electrode.

519 citations

Journal ArticleDOI
TL;DR: In this paper, a detailed description of deep X-ray lithography and an overview of the variety of microstructure products fabricated using the LIGA technique has been presented, including sensors, actuators, micromechanical components, microoptical systems, electrical and optical microconnectors.

218 citations

Journal ArticleDOI
TL;DR: In this paper, an experimental study on the machining of deep microholes by EDM is presented, which is based on a horizontal EDM using water as the dielectric, the electrode being formed by the WEDG method, the result shows the applicability of this technique to the industrial production of microholes with the depth ten times the diameter which ranges down to 50μm.

113 citations

Journal ArticleDOI
TL;DR: In this article, the main objective of the proposed research is the development of a production technology for three-dimensional micromechanical structures together with a study of the mechanical properties of these structures.
Abstract: Currently, nearly all microcomponents are fabricated by micro-electronic production technologies like etching, deposition and other (photo) lithographic techniques. In this way, main emphasis has been put on surface micromechanics. The major challenge for the future will be the development of real three-dimensional microstructures. The main objective of the proposed research is the development of a production technology for three-dimensional micromechanical structures together with a study of the mechanical properties of these structures. Electrodischarge machining (EDM) is a versatile technique which is very well suited for machining complex microstructures. This paper starts with an overview of EDM technology, the current state-of-the-art of micro EDM, and a comparison of EDM with other micromachining technologies. Afterwards, the basic parameters for EDM of silicon are derived. It will be demonstrated that EDM of silicon is not only feasible, but also forms an interesting, powerful and complementary alternative to traditional silicon micromachining.

108 citations

Journal ArticleDOI
TL;DR: In this paper, a combined machining method, micro ultrasonic machining (micro-USM), is proposed for the fabrication of three-dimensional (3D) microstructures with high aspect ratios.
Abstract: A combined machining method, micro ultrasonic machining (micro-USM), is proposed here for the fabrication of three-dimensional (3D) microstructures with high aspect ratios. Wire electro-discharge grinding (WEDG) and electro-discharge machining (EDM) are combined onto the USM machine to provide a capability of making co-axial microtools for USM and, thereafter, microholes as small as 15 μm in diameter and a variety of high-aspect-ratio microstructures on brittle materials have been achieved for the first time by optimizing the ultrasonic machining processes. The combination of WEDG, EDM and USM on a micro-USM machine also makes possible the construction of complete 3D micromachines within one total manufacturing process. With this method, a 3D micro center-pin bearing air turbine has been successfully developed. The design, fabrication and testing issues are described in this paper.

90 citations