Development, analysis and application of an actuated variable tool electrode for die-sinking EDM - VariSink4EDM

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Die-sinking Electrical Discharge Machining (EDM) is one of the most applied manufacturing processes in the German tool- and mould-making industry. Complex designed tool electrodes, manufactured by costly and time-consuming machining, are often required. As a result, the time exposure for manufacturing of electrodes and machine setup is often higher than for the EDM process. Based on the state of the art, an innovative tool electrode concept for roughing in EDM has been derived, which should be implemented in this project. The main objective of the research project is to provide basic knowledge on the use of bundled and variably adjustable single electrode tool segments in the EDM process. This requires the development, implementation and analysis of a novel, highly innovative actuated variable tool electrode. The concept contains the bundling of 25 square rod segments that can be shifted individually by friction-locked single actuators. Therefore, the actuated segments can form a needed 3D shape while additional machining and machine setup is avoided. The chamfering of selected segments enables the advantage of inner flushing when using die-sinking electrodes. Due to the actuating concept, novel flushing strategies can be explored. Experiments will be conducted to study the material and process behavior of the bundled tool segments tool electrode. Accompanying, cross section conformable linear direct drives will be developed. These not only provide the individual positioning of each tool segment before and wear compensation during the process, but are also able to execute a high-frequency motion of the segments for the realization of the new flushing strategies. The capacitive behavior of the EDM process should be used to develop an optimized process control. This is based on self-sensing estimation methods, with which in-situ an optimized working gap with inherent wear compensation can be set, as well as an automated initiation of the flushing process. At the end of the first funding period, an innovative and variable actuable tool electrode is available for roughing operations with die-sinking EDM and a novel flushing concept is implemented.