Please use this identifier to cite or link to this item: https://doi.org/10.1243/09544054JEM1718
Title: On-machine fabrication of high-aspect-ratio micro-electrodes and application in vibration-assisted micro-electrodischarge drilling of tungsten carbide
Authors: Jahan, M.P.
Rahman, M. 
Wong, Y.S. 
Fuhua, L.
Keywords: Block-μEDM process
High-aspect-ratio micro-electrodes
Tungsten carbide
Turning-μEDM hybrid process
Vibration-assisted micro-EDM
Issue Date: 1-May-2010
Source: Jahan, M.P., Rahman, M., Wong, Y.S., Fuhua, L. (2010-05-01). On-machine fabrication of high-aspect-ratio micro-electrodes and application in vibration-assisted micro-electrodischarge drilling of tungsten carbide. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 224 (5) : 795-814. ScholarBank@NUS Repository. https://doi.org/10.1243/09544054JEM1718
Abstract: The concept of fabricating on-machine high-aspect-ratio micro-electrodes arises from the need to fabricate small and deep micro-holes in micro-electrical discharge machining (micro-EDM). In the present study, investigations are conducted on the fabrication of high-aspect-ratio micro-electrodes using two simple and cost-effective micro-EDM-based processes: the 'turning-μEDM' hybrid process and the 'moving-electrode-block-μEDM' process. Process descriptions and important aspects for successful fabrication of high-aspect-ratio micro-electrodes are discussed. In addition, the application of these micro-electrodes in the fabrication of deep micro-holes in tungsten carbide using normal micro-EDM and vibration-assisted micro-EDM is presented. It is found that the turning-μEDM process can generate finer micro-electrodes for easily machinable materials such as brass, but its application to the machining of deep micro-holes in tungsten Carbide is limited by the extreme tool wear of the brass electrode. The block-μEDM process can generate microelectrodes with hard, difficult-to-cut, and high-melting-point materials such as copper tungsten (alloy) and tungsten with much higher aspect ratios. However, the taper angle of the fabricated micro-electrodes is a common problem in the stationary block-μEDM process. This problem is reduced to a great extent by using block-μEDM with a moving electrode. Micro-holes with an aspect ratio of 16.7 are achieved using vibration-assisted micro-EDM with the fabricated tungsten micro-electrode machined by the moving-electrode-block- μEDM process. © 2010 Authors.
Source Title: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
URI: http://scholarbank.nus.edu.sg/handle/10635/61006
ISSN: 09544054
DOI: 10.1243/09544054JEM1718
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