Theoretical and Experimental Study of Debris Removal and Tool Wear in Micro Electro Discharge Machining (Micro-EDM)

微细放电加工 (Micro-EDM) 中碎片去除和刀具磨损的理论与实验研究

• 批准号: 0928873
• 负责人: Kamlakar Rajurkar
• 金额: $ 25万
• 依托单位: University of Nebraska-Lincoln
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2009
• 资助国家: 美国
• 起止时间: 2009-09-01 至 2012-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0928873&HistoricalAwards=false
• 关键词: Theoretical; Experimental; Study; Debris; Removal

The research objective of this project is to increase process productivity, reliability and economy of micro electro discharge machining process for making micro scale size critical parts used in electronic, automotive and medical device industries. The formation of debris at the micro gap and tool wear affect the productivity, accuracy, reliability and economy of machined micro components. The approach involves establishing a comprehensive data base and fundamental understanding of debris formation and tool wear. Therefore, a theoretical and experimental study of micro electro discharge machining process will be conducted to understand and model debris formation at the gap and tool wear. The machining rate, tool wear, tool geometry and debris size and shape will be measured for various machining parameters and work and tool materials. The contamination models used in waste water disposal will be applied with appropriate modification to model debris concentration.Knowledge of debris removal gained from this study is expected to have a transformative effect on the design and development of micro fluidic transportation systems for future hybrid/micromachining processes. This research project will extend the capability of micro electro discharge machining especially for high aspect ratio micromachining and freeform micromachining which will be very useful for United States die and mold making, electronic and medical devices manufacturing industries. The research results will be shared with students, academic researchers and industry practitioners via University of Nebraska web site.

本项目的研究目标是提高微细电火花加工工艺的生产率、可靠性和经济性，以制造用于电子、汽车和医疗器械行业的微细尺寸关键零件。微小间隙处的磨屑形成和刀具磨损影响着加工的微小零件的生产率、精度、可靠性和经济性。该办法涉及建立一个全面的数据库和对碎片形成和工具磨损的基本了解。因此，我们将对微细电火花加工过程进行理论和实验研究，以了解缝隙处的磨屑形成和刀具磨损情况，并对其进行模拟。对于不同的加工参数以及加工功和刀具材料，将测量加工速度、刀具磨损、刀具几何形状以及磨屑大小和形状。废水处理中使用的污染模型将经过适当的修改后应用于磨屑浓度的建模。从这项研究中获得的磨屑清除知识有望对未来混合/微加工工艺的微射流传输系统的设计和开发产生革命性的影响。该研究项目将扩大微细电火花加工的能力，特别是高深宽比微加工和自由曲面微加工，这对美国模具制造、电子和医疗器械制造行业将非常有用。研究结果将通过内布拉斯加大学的网站与学生、学术研究人员和行业从业者分享。