Die-sink EDM in meso-micro machining

Abstract

Micro EDM has been identified since more than a decade as suitable process for machining complex shaped structures with high aspect ratio, though only through variations of EDM such as micro EDM milling, micro EDM drilling, coated electrodes etc. In the current paper, we present the research focused on analysing the capability for implementation of die-sink EDM in meso - micro scale machining (structures with surface area smaller than 10mm2 down to 0.05mm2) by concentrating on primary process parameters to obtain high material removal rate, low tool electrode wear with high form accuracy and precision. Graphite electrodes were mill machined in meso-micro scale with high precision and accuracy. Low tool wear technology was developed for using graphite electrodes in meso-micro EDM offering economical and energy efficient solution in meso-micro scale machining.