Presentation Title

Experimental Study on Dry Micro Electrical Discharge Machining Process

Start Date

November 2016

End Date

November 2016

Location

HUB 302-#108

Type of Presentation

Poster

Abstract

Electrical Discharge Machining (EDM) is a thermal-erosive machining process which removes the material with the help of electrical sparks produced between the workpiece and the electrode in presence of a dielectric medium. The material removal process during EDM depends only on the electrical conductivity of the workpiece and is independent of its mechanical properties. Because of this EDM is considered as the preferred process to machine extremely hard and strong metals and metallic alloys. Micro Electrical Discharge Machining (μEDM) is a micron scale derivative of EDM process that can machine 3D structure on difficult-to-machine materials. μEDM is normally performed in the presence of a liquid dielectric medium such as kerosene, deionized water or other hydrocarbon oils. However, μEDM has few disadvantages such as high tool wear rate, high residual thermal stresses, thick white layer formation and lower precision. Moreover, μEDM is a non-environmental friendly process because of the use of dielectric liquids causing harmful effects such as health hazards, skin irritation and toxicity. Using gas instead of liquid as the dielectric medium could potentially minimize these limitations of μEDM. This research thus explores micromachining capabilities of Dry Micro Electrical Discharge Machining (Dry μEDM) process. Dry μEDM process would be a green and environmental friendly process which has advantages such as lower tool wear, high material removal rate, thin white-layer formation, lower residual thermal stresses and higher precision. The research involves extensive experimental studies on an in-house built Dry μEDM using nitrogen gas as the dielectric medium. The research outcome is expected to expand the current capabilities of μEDM into advanced engineering applications such as machining ultraprecision electronic components.

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Nov 12th, 4:00 PM Nov 12th, 5:00 PM

Experimental Study on Dry Micro Electrical Discharge Machining Process

HUB 302-#108

Electrical Discharge Machining (EDM) is a thermal-erosive machining process which removes the material with the help of electrical sparks produced between the workpiece and the electrode in presence of a dielectric medium. The material removal process during EDM depends only on the electrical conductivity of the workpiece and is independent of its mechanical properties. Because of this EDM is considered as the preferred process to machine extremely hard and strong metals and metallic alloys. Micro Electrical Discharge Machining (μEDM) is a micron scale derivative of EDM process that can machine 3D structure on difficult-to-machine materials. μEDM is normally performed in the presence of a liquid dielectric medium such as kerosene, deionized water or other hydrocarbon oils. However, μEDM has few disadvantages such as high tool wear rate, high residual thermal stresses, thick white layer formation and lower precision. Moreover, μEDM is a non-environmental friendly process because of the use of dielectric liquids causing harmful effects such as health hazards, skin irritation and toxicity. Using gas instead of liquid as the dielectric medium could potentially minimize these limitations of μEDM. This research thus explores micromachining capabilities of Dry Micro Electrical Discharge Machining (Dry μEDM) process. Dry μEDM process would be a green and environmental friendly process which has advantages such as lower tool wear, high material removal rate, thin white-layer formation, lower residual thermal stresses and higher precision. The research involves extensive experimental studies on an in-house built Dry μEDM using nitrogen gas as the dielectric medium. The research outcome is expected to expand the current capabilities of μEDM into advanced engineering applications such as machining ultraprecision electronic components.