Micro-electrode discharge machining: Factors affecting the quality of electrodes produced on the machine through the process of wire electro-discharge machining

Abstract

The introduction of a technique for on-the-machine electrode generation, utilizing wire electro-discharge grinding (WEDG) has broadened the application area of the microelectrode discharge machining (μEDM) process. The present paper studies the capabilities of the WEDG process for manufacturing micro-electrodes. The influence of electrode material, machining strategy, and machine accuracy on the quality of electrodes produced on-the-machine is investigated and a solution is proposed to improve this process. The experimental results reveal the limitations of the WEDG dressing and the effects of electrode material, machining strategy, and machine accuracy on electrode quality, achievable aspect ratio, and surface finish. The study shows that by employing an optical verification system the accuracy of the dressing process could be improved significantly.