Journal
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
Volume 271, Issue -, Pages 455-462Publisher
ELSEVIER SCIENCE SA
DOI: 10.1016/j.jmatprotec.2019.04.024
Keywords
Laminated disc electrode; EDM; Wear; Micro groove; Micro channel
Funding
- National Natural Science Foundation of China [51805333, 51575360]
- Natural Science Foundation of Guangdong Province [2017A030313309]
- Science and Technology Innovation Commission Shenzhen [JCYJ20170817094310049, JSGG20170824111725200]
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Tool electrode wear varying with different materials in electrical discharge machining (EDM) is unavoidable, thus inevitably reducing the machining quality and accuracy of microstructures. To convert this disadvantageous phenomenon into a beneficial process, the paper proposed a wear-variation EDM (WV-EDM) approach to fabricate a laminated disc electrode (LDE) with stable-shape micro channels on the outer edge surface; this electrode was subsequently used to machine micro grooves on workpieces by EDM. The WV-EDM formation of the LDE, the relationship between relative volume wear rate of the disc foils and the machining depth, and flow field distribution in the machining gap of the LDE during processing were investigated. The results show that the method proposed herein could reliably produce LDEs with stable micro channels on the outer edge surfaces that could subsequently be employed to continuously machine micro groove arrays with the same machining depth on the same material workpiece by EDM, and especially LDE reshaping was unnecessary. Additionally, the pump effect of the vortex, located in the flow field between micro channels on the LDE and workpiece, was beneficial for debris removal. Using the proposed method, micro groove arrays and columnar microstructures were successfully fabricated on Ti-6Al-4V alloy workpieces.
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