The ability to remove chip volumes in micro-nano scale has enabled implementation of electrical discharge machining (EDM) in high precision and micro-machining of difficult to machine electrically conductive materials, such as metals and ceramics. Despite of its wide spread application in tool making and precision applications, the limited process understanding limits exploitation of the EDM process capabilities. In current work, scaling effects caused due to the electrode projection area and erosion depth have been analysed for the single and multiple discharges. Material removal caused by a single discharge has been simulated using a heat conduction model and validated through the experimental results. However, the paradigm shift in the optimal pulse duration value to obtain high material removal rate observed for multiple discharge process does not correlate to the single discharge removal values, even when considering the discharge frequencies during the erosion. It has been evaluated that this shift originates from the decrease in the efficiency of material removal per spark in actual erosion conditions. Different plasma states generated due to the limited dielectric availability in micro cavities and gas bubble dynamics have been proposed to be the cause for origination of the scaling effects in meso-micro EDM.
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ASME 2013 International Mechanical Engineering Congress and Exposition
November 15–21, 2013
San Diego, California, USA
Conference Sponsors:
- ASME
ISBN:
978-0-7918-5619-2
PROCEEDINGS PAPER
Investigation of the Scaling Effects in Meso-Micro EDM
Umang Maradia,
Umang Maradia
ETH Zurich, Zurich, Switzerland
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Konrad Wegener,
Konrad Wegener
ETH Zurich, Zurich, Switzerland
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Josef Stirnimann,
Josef Stirnimann
Inspire AG, ETH Zurich, Zurich, Switzerland
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Reto Knaak,
Reto Knaak
Agie Charmilles SA, Losone, Switzerland
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Marco Boccadoro
Marco Boccadoro
Agie Charmilles SA, Losone, Switzerland
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Umang Maradia
ETH Zurich, Zurich, Switzerland
Konrad Wegener
ETH Zurich, Zurich, Switzerland
Josef Stirnimann
Inspire AG, ETH Zurich, Zurich, Switzerland
Reto Knaak
Agie Charmilles SA, Losone, Switzerland
Marco Boccadoro
Agie Charmilles SA, Losone, Switzerland
Paper No:
IMECE2013-63160, V02BT02A038; 10 pages
Published Online:
April 2, 2014
Citation
Maradia, U, Wegener, K, Stirnimann, J, Knaak, R, & Boccadoro, M. "Investigation of the Scaling Effects in Meso-Micro EDM." Proceedings of the ASME 2013 International Mechanical Engineering Congress and Exposition. Volume 2B: Advanced Manufacturing. San Diego, California, USA. November 15–21, 2013. V02BT02A038. ASME. https://doi.org/10.1115/IMECE2013-63160
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