Modeling Debris Motion in Vibration Assisted Reverse Micro Electrical Discharge Machining Process (R-MEDM)
- 7 August 2014
- journal article
- Published by Institute of Electrical and Electronics Engineers (IEEE) in Journal of Microelectromechanical Systems
- Vol. 24 (3), 661-676
- https://doi.org/10.1109/jmems.2014.2343227
Abstract
Reverse microelectrical discharge machining (R-MEDM) process is a recent variant of microelectrical discharge machining process capable of fabricating high aspect ratio arrayed microfeatures and textured surfaces. Efficient flushing of the debris particles from the interelectrode gap is essential for process stability, but extremely small interelectrode gaps (~5 μm) make the dispelling of debris difficult, rendering the R-MEDM process infeasible for machining difficult-to-erode materials and creation of engineered/textured surfaces. It has been experimentally observed that the electrode vibrations facilitate the flushing of debris particles and improve the erosion rate, surface morphology, and dimensional accuracy of the machined features. Despite the obvious advantages, the vibration-assisted R-MEDM process, specifically the debris motion and dielectric flow under the effect of vibration, is not very well understood. Consequently, this paper is focused on computational modeling of the debris motion and its interaction with the dielectric fluid under low-amplitude vibrations imparted via a magnetorestrictive actuator. The effects of frequency and amplitude of the electrode vibration on the debris motion have been quantified. The higher local debris velocities and oscillatory motion due to flow reversal potentially reduce the debris agglomeration. As a result, the normal discharge duration, which is responsible for the material erosion, is increased and fabrication of arrayed features on difficult-to-erode materials and creation of surface texture over large areas become feasible.Keywords
This publication has 22 references indexed in Scilit:
- Experimental Characterization of Vibration-Assisted Reverse Micro Electrical Discharge Machining (EDM) for Surface TexturingPublished by ASME International ,2012
- Analysis of the effect of vibrations on the micro-EDM process at the workpiece surfacePrecision Engineering, 2011
- Experimental research on vibration assisted EDM of micro-structures with non-circular cross-sectionJournal of the American Academy of Dermatology, 2008
- Machining characteristics of magnetic force-assisted EDMInternational Journal of Machine Tools and Manufacture, 2008
- Experimental Study of Microelectrode Array and Micro-Hole Array Fabricated by Ultrasonic Enhanced Micro-EDMPublished by Test accounts ,2007
- Sub-nanosecond monitoring of micro-hole electrical discharge machining pulses and modeling of discharge ringingInternational Journal of Machine Tools and Manufacture, 2006
- A study on the machining of high-aspect ratio micro-structures using micro-EDMJournal of the American Academy of Dermatology, 2003
- Ultrasonic vibration assisted electro-discharge machining of microholes in NitinolJournal of Micromechanics and Microengineering, 2003
- A study of ultrasonically aided micro-electrical-discharge machining by the application of workpiece vibrationJournal of the American Academy of Dermatology, 2003
- Effects of flushing on electro-discharge machined surfacesJournal of the American Academy of Dermatology, 1995