Micro-Electrode Fabrication Process Using EDM

Abstract

Micro-machining is a fundamental process for manufacturing parts and products with dimensions of between 1 to 999 μm. Micro-Electro Discharge Machining (micro-EDM) has been used for producing of parts, molds, dies, cavities and complex three dimensional shape regardless of hardness and strength. Micro-electrodes are required for these purposes and usually micro EDM machines are used for fabricating them. Moving block electro discharge grinding (Moving BEDG) is one of the processes that can be used to fabricate micro-electrode. In this study a conventional EDM machine is used for fabricating the micro-electrode. Based on the characteristics of this machine some changes need to be applied to the moving BEDG for micro-electrode fabrication. Modification made to the moving BEDG include changing the direction of movement and control gap, use of roughing, semi finishing and finishing electrodes in one electrode. Consequently set up and machining time was decreased due to the use of roughing, semi finishing and finishing parameters. Finally, high aspect ratio micro electrode with diameter of 160.8μm was fabricated. As this process is simple and does not require high investment for special equipment; it can be used even by an ordinary workshop equipped with a conventional EDM machine.