In order to minimize cost of machining, modern aerospace components are highly unitized to utilize functions of multi-axes CNC machining centres. However, PCD tools are preferred for machining of titanium alloys and metal matrix composites but they are hard to grind. A new fast material removal electric discharge machine suitable for small PCD workpiece machining has been developed from an innovative model consisting both high and low frequency response actuators and a dual stage non-linear control algorithm. This innovative approach has been proved successful in the single axis machine prototype and the fast material removal rate has been verified a series of tests and the outcomes were verified.
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