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Micro-EDM: Process effects on the tool wear ratio

: Schubert, A.; Wolf, N.; Zeidler, H.

Postprint urn:nbn:de:0011-n-1747381 (1.0 MByte PDF)
MD5 Fingerprint: aeb50b9bfe6c62dca426ff2e2faadb7c
Created on: 2.8.2011

Spaan, H. ; European Society for Precision Engineering and Nanotechnology -EUSPEN-:
11th International Conference of the European Society for Precision Engineering and Nanotechnology 2011. Proceedings. Vol.2 : May 23rd - 26th 2011, Como, Italy; conference proceedings
Bedford: Euspen, 2011
ISBN: 978-0-9553082-9-1
European Society for Precision Engineering and Nanotechnology (EUSPEN International Conference) <11, 2011, Como>
Conference Paper, Electronic Publication
Fraunhofer IWU ()
micro-EDM; tool wear; high aspect ratio; microstructuring

The fabrication of high aspect ratio microstructures is very challenging, especially when the work piece material is hard to machine. Electro Discharge Machining (EDM) offers a contact- and nearly force free way of micromachining and is therefore an appropriate means to producing microstructures. One key obstacle for a precise machining by micro-EDM is the tool wear. When ED-machining microstructures process speed, stability and thus tool wear are related to the aspect ratio of the structures. In this study, tool wear ratio within different stages of the EDM process is analysed when machining high aspect ratio micro bores in steel. Experiments with bores of different depths show the correlation between the stage of the process and the flushing conditions on the one hand and the tool wear ratio on the other hand. Thus, it is possible to find and apply optimized parameters for the different process stages. A better understanding of the tool wear will help to minimize it, reducing the cost of the tools and enhancing the precision of the process. This also shall allow an enhancement of the process speed because the need for flushing material out of the bore is reduced by the amount of tool material that can be saved.