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

该项目的研究目标是提高微电火花加工工艺的工艺生产率、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尺寸关键部件。微间隙处碎屑的形成和刀具的磨损影响加工微部件的生产率、精度、可靠性和经济性。该方法包括建立一个全面的数据库和对碎屑形成和工具磨损的基本理解。因此，将对微细电火花加工过程进行理论和实验研究，以了解和模拟间隙处的碎屑形成和刀具磨损。将测量各种加工参数、工件和刀具材料的加工速度、刀具磨损、刀具几何形状和碎屑大小和形状。污水处理中使用的污染模型将在适当修改模型后应用于碎屑浓度。从这项研究中获得的碎片去除知识预计将对未来混合/微加工工艺的微流体输送系统的设计和开发产生变革性影响。本课题的研究将进一步扩展微细电火花加工的能力，特别是在高纵横比微细加工和自由曲面微细加工方面，对美国模具制造、电子和医疗器械制造等行业具有重要意义。研究结果将通过内布拉斯加大学网站与学生、学术研究人员和行业从业者分享。

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.