Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining
Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining
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DOI：
10.1016/j.ijmachtools.2005.03.017
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发表时间：
2006
影响因子：
14
通讯作者：
Hung-Sung Liu;B. Yan;Chien-Liang Chen;F. Huang
中科院分区：
文献类型：
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作者：
Hung-Sung Liu;B. Yan;Chien-Liang Chen;F. Huang
本研究提出一种利用微细电火花加工与高频颤化研磨相结合的方法来改善微细孔的表面粗糙度。微细电火花加工是一种成熟的加工选择，用于制造几何形状复杂的硬质或超韧材料小零件（直径小于100μm）。然而，微细电火花加工导致在加工表面上形成的重铸层被放电坑和微裂纹覆盖，导致表面质量差。这影响了加工的微孔直径，并严重破坏了几何形状的精度。将微细电火花加工与高频电火花磨削相结合的方法应用于高镍合金的加工。SEM照片和表面粗糙度测量表明，HFDG法可使表面粗糙度从2.12 μ mRmax降低到0.85μ mRmax，并消除了微裂纹。实验结果表明，在峰值电流500 mA下，采用40 V高压静电放电进行微细电火花加工，经过6- 8 min的研磨加工，可以获得精确的孔形和良好的表面质量。
This research presents a novel process using micro electro-discharge machining (micro-EDM) combined with high-frequency dither grinding (HFDG) to improve the surface roughness of micro-holes. Micro-EDM is a well-established machining option for manufacturing geometrically complex small parts (diameter under 100μm) of hard or super-tough materials. However, micro-EDM causes the recast layer formed on the machined surface to become covered with discharge craters and micro-cracks, resulting in poor surface quality. This affects the diameter of the micro-hole machined and undermines seriously the precision of the geometric shape. The proposed method that combines micro-EDM process with HFDG is applied to machining high-nickel alloy. As observed in SEM photographs and surface roughness measurement, HFDG method can reduce surface roughness from 2.12 to 0.85μm Rmax with micro-cracks eliminated. Our results demonstrated that micro-holes fabricated by micro-EDM at peak current 500mA followed by HFDG at 40V can achieve precise shape and good surface quality after 6–8min of lapping.