Micro electro discharge machining of tungsten carbide and polycrystalline diamond : an experimental analysis of process parameters

Abstract

Electro discharge machining (EDM) is a manufacturing process where material removal is realized through electrical discharges between two conductive materials without applying any external forces. As a result, high aspect ratio micro features on difficult-to-cut materials such as tungsten carbide and polycrystalline diamond can be obtained. In this study, influences of micro-EDM process parameters such as voltage, capacitance, and rotational speed on material removal rate and surface quality have been investigated using experimental techniques. Experimental results have revealed that capacitance and voltage applied during EDM process have significant effects on material removal rate and surface roughness. Regression models have been calculated to represent the relationships between process inputs and outputs which can be used to calculate processing time and to predict surface finish. In addition, a process planning software for wire-EDM process, which is capable of generating necessary tool paths during fabrication of micro tools, has been developed. The software is also capable of producing the solid model of the micro tools which can be utilized in computer aided engineering applications.