Geometric simulation based tool wear compensation in micro die-sinking EDM process
Geometric simulation based tool wear compensation in micro die-sinking EDM process
复制标题
微细电火花成型加工中基于几何模拟的刀具磨损补偿
DOI：
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发表时间：
2014
期刊：
影响因子：
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通讯作者：
Sang Jo Lee
中科院分区：
文献类型：
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作者：
Segon Heo;Tae Gon Kim;Chan Hong Lee;B. Min;Sang Jo Lee
INTRODUCTION The die-sinking EDM process, a machining process widely used in industrial fields, casts a desired shape by using a tool electrode that is in the opposite shape to that desired. Because it is easily applied to machine a three-dimensional shape, the die-sinking EDM process is largely used for machining a die and mold. There has recently been an increase in demand for the minimization of parts in the fields of biomedical, optical science, and electronics; this has allowed the micro die-sinking EDM process to be widely used in various applications along with other micromachining methods [1]. Research on the conventional die-sinking EDM process has focused attention on predicting and improving the material removal rate (MRR) as well as predicting and decreasing surface roughness and tool wear. However, in the case of the micro die-sinking EDM process, research on tool wear and its influence on the machined shape is a more immediate requirement. Because the EDM process is based on thermal energy, tool wear during the EDM process is an unavoidable problem that deteriorates the form accuracy of the products. In general, the micro-EDM process has a lower material removal rate than the mechanical cutting processes [2]. Increasing the discharge energy to increase the machining speed results in a higher tool wear ratio [3]. Therefore, an increased material removal rate causes more tool wear and machining error. In addition, as machining progresses, an edge of the tool becomes more worn and becomes round [4]. This is because the tool removes a larger amount of workpiece per unit area at edges. In particular, the tool wear in the micro die-sinking EDM process is greater than that in the conventional die-sinking EDM process [1]. This is because in the micro-sinking EDM process, the discharge energy and resulting size of the crater do not decrease as much as the tool and workpiece become small. In this study, the geometric simulation based tool wear compensation method in micro diesinking EDM process is proposed. The proposed geometric simulation precisely represents the geometries of a machined workpiece and the evolution of the tool shape caused by tool wear during the machining. Therefore, the simulation can be used for tool wear compensation. A compensation method for the tool shape design with which a desired shape is machined is proposed, taking tool wear into consideration.
