Development, analysis and application of surface-oxidized tool electrodes for optimization of electro-discharge drilling – OXI4EDM

中型模具制造行业作为德国最重要的分支之一，由于政治和经济的发展，在全球市场上面临着新的挑战。为了确保竞争力，德国模具制造行业必须通过使用创新的生产技术来保持其卓越的质量和生产率。电火花钻孔(EDD)被用于模具和工具制造，因为它可以加工任何导电材料，无论其硬度和强度如何。由于短路和二次放电，与工艺有关的碎片在侧隙中的冲洗会导致负面的工艺损害。因此，该项目的目的是通过开发、分析和使用创新的铜和黄铜表面氧化工具电极来优化EDD。通过电极表面的氧化，工具侧表面几乎以先前未反应的方式电绝缘，以便最小化在侧间隙中发生的短路和侧放电。根据在研究项目中获得的知识，将有可能以极大的缩短加工时间、高纵横比和提高质量(例如降低锥度)来生产钻孔。

The medium-sized mold and tool making industry, as one of the most important branches in Germany, is confronted with new challenges in global markets due to political and economic developments. In order to ensure competitiveness, the German mold and tool making industry has to maintain its superior quality and productivity by using innovative production technologies.Electro-discharge drilling (EDD) is used for mold and tool making because it’s possible to machine any electrically conductive material, regardless of hardness and strength. The process-related flushing of debris across the side gap leads to negative process impairments due to short circuits and secondary discharges. The aim of the project is therefore the optimization of EDD by the development, analysis and use of innovative surface-oxidized tool electrodes made of copper and brass. By means of the oxidation of the electrode surfaces, the tool lateral surfaces are almost electrically insulated in a previously unreacted manner in order to minimize the shorts and side discharges occurring in the side gap. Based on the knowledge gained in the research project it will be possible to produce drill holes with a greatly reduced process time, with a high aspect ratio, and improved quality (for instance reduced conicity).