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Research Papers

Optimization of Planetary Movement Parameters for Microhole Drilling by Micro-Electrical Discharge Machining

[+] Author and Article Information
Zuyuan Yu

e-mail: zyu@dlut.edu.cn

Jianzhong Li

Key Laboratory for Precision,
and Non-Traditional,
Machining Technology of Ministry of Education,
School of Mechanical Engineering,
Dalian University of Technology,
Dalian 116024, China

Wataru Natsu

Department of Industrial Technology
and Innovation,
Graduate School of Engineering,
Tokyo University of Agriculture and Technology,
Tokyo 184-0012, Japan

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF Micro- AND Nano-Manufacturing. Manuscript received May 11, 2013; final manuscript received July 25, 2013; published online August 13, 2013. Assoc. Editor: Hitoshi Ohmori.

J. Micro Nano-Manuf 1(3), 031007 (Aug 13, 2013) (5 pages) Paper No: JMNM-13-1026; doi: 10.1115/1.4025160 History: Received May 11, 2013; Revised July 25, 2013

Microholes are widely used in industrial products, such as engine nozzles and filters for biomedical industry. Electrical discharge machining (EDM) is one of processes to drill microholes in alloy with high aspect ratio. However, the achievable aspect ratio of a microhole by micro-EDM is limited. To improve the aspect ratio of a microhole drilled by micro-EDM, the planetary movement of electrode is applied during machining. It was found that the machining efficiency of microhole drilling can be further improved by proper setting of planetary movement of electrode, such as the electrode feed rate and movement speed of electrode in XY plane. In this paper, a theoretical model is proposed to optimize parameters of the planetary movement of electrode. Microholes are drilled aided with planetary movement using different machining parameters to verify the model. Experimental results agree with theoretical values, which indicate the validity of the proposed model. This model provides certain theoretical basis for machining parameter selection when microholes are drilled aided with planetary movement.

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References

Masuzawa, T., 2000, “State of the Art of Micromachining,” CIRP Ann., 49(2), pp. 473–488. [CrossRef]
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Li, L., Diver, C., Atkinson, J., Giedl-wagner, R., and Helml, H. J., 2006, “Sequential Laser and EDM Micro-Drilling for Next Generation Fuel Injection Nozzle Manufacture,” CIRP Ann., 55(1), pp. 179–182. [CrossRef]
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Hung, J. C., Lin, J. K., Yan, B. H., Liu, H. S., and Ho, P. H., 2006, “Using a Helical Micro-Tool in Micro-EDM Combined With Ultrasonic Vibration for Micro-hole Machining,” J. Micromech. Microeng., 16(12), pp. 2705–2713. [CrossRef]
Yu, Z. Y., Zhang, Y., Li, J., Luan, J., Zhao, F., and Guo, D., 2009, “High Aspect Ratio Micro-Hole Drilling Aided With Ultrasonic Vibration and Planetary Movement of Electrode by Micro EDM,” CIRP Ann., 58(1), pp. 213–218. [CrossRef]
Bamberg, E., and Heamawatanachai, S., 2009, “Orbital Electrode Actuation to Improve Efficiency of Drilling Micro-Holes by Micro-EDM,” J. Mater. Process. Technol., 209(4), pp. 1826–1834. [CrossRef]

Figures

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Fig. 2

The relationship between electrode feed and discharge gap

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Fig. 1

Tool path of planetary movement of electrode

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Fig. 3

A horizontal micro-EDM

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Fig. 4

Microhole of 120.41 μm in diameter drilled by micro-EDM with planetary movement

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Fig. 5

Electrode of 53.04 μm in diameter after hole drilling

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Fig. 6

Microhole of 100.91 μm in diameter drilled by micro-EDM without planetary movement

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Fig. 7

Relationship between MRR and velocity of electrode planetary movement: (a) diameter of electrode (59.37 μm), capacitance (470 pF), radius of planetary movement (15 μm); (b) diameter of electrode (82.44 μm), capacitance (470 pF), radius of planetary movement (10 μm); (c) diameter of electrode (60.67 μm), capacitance (3300 pF), radius of planetary movement (10 μm)

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Fig. 8

Relationship between MRR and k: (a) diameter of electrode (61.00 μm), capacitance (100 pF), radius of planetary movement (10 μm); (b) diameter of electrode (61.56 μm), capacitance (470 pF), radius of planetary movement (10 μm); (c) diameter of electrode (62.86 μm), capacitance (1000 pF), radius of planetary movement (15 μm); (d) diameter of electrode (80.00 μm), capacitance (1000 pF), radius of planetary movement (10 μm)

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