An Investigation into Accumulative Difference Mechanism in Time and Space for Material Removal in Micro-EDM Milling.
TL;DR: In this article, a theoretical model is developed to simulate the micro-EDM milling process with a straight-line single path, and the simulation results for a cylindrical electrode at the two rotational speeds of 0 (nonrotating) and 300 rpm are compared, while the results for the cylinrical electrode and a square electrode at a rotation speed of 0 are also compared to verify that different process parameters generate accumulative differences in the time and space of material removal.
Abstract: In micro-electrical discharge machining (micro-EDM) milling, the cross-section of the microgroove machine is frequently not an ideal rectangle. For instance, there are arc shapes on the bottom and corners, and the sidewall is not steep. The theoretical explanation for this phenomenon is still lacking. In addition to the tip discharge effect, the essential reason is that there is an accumulative difference in time and space during the shape change process of a tool electrode and the microstructure formation on a workpiece. The process parameters are critical influencing factors that determine this accumulative difference. Therefore, the accumulative difference mechanism in time and space is investigated in this paper, and then a theoretical model is developed to simulate the micro-EDM milling process with a straight-line single path. The simulation results for a cylindrical electrode at the two rotational speeds of 0 (nonrotating) and 300 rpm are compared, while the results for a cylindrical electrode and a square electrode at a rotation speed of 0 are also compared to verify that different process parameters generate accumulative differences in the time and space of material removal. Finally, micro-EDM milling experiments are carried out to verify the simulation model. The maximum mean relative deviation between the microgroove profiles of simulation results and those of experiments is 11.09%, and the profile shapes of simulations and experiments have a good consistency. A comparative experiment between a cylindrical electrode and a hollow electrode is also performed, which further verifies the mechanism revealed in the study. Furthermore, the cross-section profile of a microgroove can be effectively controlled by adjusting the process parameters when utilising these accumulative differences through fabricating a microgroove with a V-shaped cross-section by a square electrode and a microgroove with a semi-circular cross-section by a cylindrical electrode. This research provides theoretical guidance for solving the problems of the machining accuracy of detail features in micro-EDM milling, for instance, to machine a microgroove with an ideal rectangular cross-section.
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TL;DR: In this article, the development trends in the fabrication of super-hydrophobic surface materials by non-traditional processing techniques are summarized and the advantage and disadvantage of the above mentioned nontraditional machining processes are discussed.
Abstract: When the water droplets are on some superhydrophobic surfaces, the surface only needs to be inclined at a very small angle to make the water droplets roll off. Hence, building a superhydrophobic surface on the material substrate, especially the metal substrate, can effectively alleviate the problems of its inability to resist corrosion and easy icing during use, and it can also give it special functions such as self-cleaning, lubrication, and drag reduction. Therefore, this study reviews and summarizes the development trends in the fabrication of superhydrophobic surface materials by non-traditional processing techniques. First, the principle of the superhydrophobic surfaces fabricated by laser beam machining (LBM) is introduced, and the machining performances of the LBM process, such as femtosecond laser, picosecond laser, and nanosecond laser, for fabricating the surfaces are compared and summarized. Second, the principle and the machining performances of the electrical discharge machining (EDM), for fabricating the superhydrophobic surfaces, are reviewed and compared, respectively. Third, the machining performances to fabricate the superhydrophobic surfaces by the electrochemical machining (ECM), including electrochemical oxidation process and electrochemical reduction process, are reviewed and grouped by materials fabricated. Lastly, other non-traditional machining processes for fabricating superhydrophobic surfaces, such as ultrasonic machining (USM), water jet machining (WJM), and plasma spraying machining (PSM), are compared and summarized. Moreover, the advantage and disadvantage of the above mentioned non-traditional machining processes are discussed. Thereafter, the prospect of non-traditional machining for fabricating the desired superhydrophobic surfaces is proposed.
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TL;DR: The second volume of the special issue on micro-electro discharge machining as mentioned in this paper confirms the growing interest in the micro-EDM technology as a suitable and efficient technology for machining novel, multi-material components, with demanding requirements in terms of precision, accuracy and productivity.
Abstract: The second volume of the Special Issue on "Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications" confirms the growing interest in the micro-EDM technology as a suitable and efficient technology for machining novel, multi-material components, with demanding requirements in terms of precision, accuracy and productivity [...].
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TL;DR: Comparisons regarding pump size, flow rate, and backpressure will help readers to decide their proper design before starting a microfluidics project.
Abstract: Microfluidics has emerged from the MEMS-technology as an important research field and a promising market. We give an overview on one of the most important microfluidic components: the micropump. In the last decade, various micropumps have been developed. There are only a few review papers on microfluidic devices and none of them were dedicated only to micropumps. This review paper outlines systematically the pump principles and their realization with MEMS-technology. Comparisons regarding pump size, flow rate, and backpressure will help readers to decide their proper design before starting a microfluidics project. Different pump principles are compared graphically and discussed in terms of their advantages and disadvantages for particular applications
566 citations
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
TL;DR: In this article, a uniform wear method for 3D micro-EDM was proposed, which maintains the original electrode shape and converts the three dimensional electrode wear to a linear one.
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TL;DR: In this article, the state-of-the-art machining technologies for three-dimensional microproducts are summarized by focusing on the methods using tools, and promising methods for machining convex and concave shapes are introduced and discussed with respect to their state of the art.
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TL;DR: LIGA, an alternative microfabrication process combining deep X-ray lithography, plating-through-mask and molding, enables the highly precise manufacture of high-aspect-ratio microstructures with large structural height ranging from hundreds to thousands of micrometers thick.
267 citations