Characterization of Pulses in Micro EDM Milling Based on Wear and Material Removal

G. Bissacco(a), J. Valentincic(b), B.D. Wiwe(a), H.N. Hansen(a)
a: Department of Manufacturing Engineering and Management (IPL), Technical University of Denmark (DTU), Produktionstorvet 2800 Kgs. Lyngby, Denmark
b: Laboratory for Alternative Technologies, Faculty of Mechanical Engineering, University of Ljubljana

Abstract

This paper presents an investigation on wear and material removal in micro EDM milling for selected process parameters combinations typical of rough and finish machining of micro features in steel using state of the art equipment. Based on discharge counting and volume measurements, electrode wear unit and material removal unit are measured for several energy levels. The influence of the accuracy of volume measurements on the electrode wear unit and material removal unit are discussed and the issues limiting the applicability of real time wear sensing in micro EDM milling are presented.