Title: Study of sudden tool failure in micro electro discharge milling

Authors: Murali M. Sundaram; Yu Liu; K.P. Rajurkar; Fuling Zhao

Addresses: School of Dynamics Systems, University of Cincinnati, Cincinnati, OH, 45221, USA ' College of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China ' University of Nebraska-Lincoln, Lincoln, NE, 68503, USA ' Key Lab. for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

Abstract: Micro electro discharge milling (MED milling) is a spark erosion method capable of micromachining prismatic and complex shapes using simple non-profiled tool. Tool wear poses major hurdle in the development of MED milling. This paper discusses the types of tool wear in MED milling and analyses factors causing exfoliation and sudden failure of micro tool. Process simulation of MED milling suggests using less viscous dielectric fluid, lower tool rotational speed and higher discharge gap to reduce the chances of unpredictable tool failure in MED milling. [Received 30 August 2011; Revised 6 February 2012; Accepted 29 March 2012]

Keywords: micro EDM; electro-discharge machining; electrical discharge machining; micro electro-discharge milling; MED milling; tool wear; tool failure; micromachining; process simulation; dielectric fluids; rotational speed; discharge gap.

DOI: 10.1504/IJMR.2013.053283

International Journal of Manufacturing Research, 2013 Vol.8 No.2, pp.121 - 134

Published online: 29 Jan 2014 *

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