Title: Micro-machining and micro-grinding with tools fabricated by micro electro-discharge machining

Authors: Chris J. Morgan, R. Ryan Vallance, Eric R. Marsh

Addresses: Department of Mechanical Engineering, University of Kentucky, Lexington, KY 40506, USA. ' Mechanical and Aerospace Engineering Department, The George Washington University, Washington, DC 20052, USA. ' Department of Mechanical and Nuclear Engineering, The Pennsylvania State University, University Park, PA 16803, USA

Abstract: This paper provides an overview of several approaches to micro-machining by mechanical and electro-discharge means of material removal. Two steps are required in machining micro features. Firstly, a custom-shaped tool is created from suitable stock. In many cases, this is carried out using a small-scale version of wire Electro-Discharge Machining (EDM) in tool materials such as sintered PolyCrystalline Diamond (PCD) or tungsten carbide. Then the micro-tool can be used as a miniature end mill, drill or abrasive wheel. Each of these mechanical machining methods can be combined with EDM to achieve a customisable surface finish and feature accuracy. Trade-offs such as tool wear, Material Removal Rate (MRR) and machining time are discussed in this paper within the context of several examples.

Keywords: micro electro-discharge machining; micro-EDM; micromachining; microgrinding; electrical discharge machining; nanomanufacturing; wire-EDM; surface finish; feature accuracy; tool wear; material removal rate; MRR; machining time; tungsten carbide; sintered PCD.

DOI: 10.1504/IJNM.2006.012196

International Journal of Nanomanufacturing, 2006 Vol.1 No.2, pp.242 - 258

Published online: 28 Jan 2007 *

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