Micro EDM process Tolerance and its Effect on Electrode Wear Compensation Methods

摘要

This paper studies the effect of the tool wear on the accuracy of the micro EDM machined surfaces where simple shaped cylindrical rotating tool-electrodes are used. The tool electrode wear affects the precision of machined micro features and causes distortion of the original tool-electrode shape and dimensions. Tool shape deformation and especially its random variations in the volumetric wear are the two main factors affecting the applicability of wear compensation methods as well as indicating the precision achievable with the micro EDM process. The shape change of the tool-electrode and the repercussions of the tool wear on the precision of the machined surfaces are analysed. The paper further investigates the electrode-tool wear influence during the micro EDM process of pure metals and the effect of the electrode wear on the process tolerance and process variability. The objective of the research is to investigate the wear behaviour of the electrodes and discuss the suitability of electrode wear compensation methods.