Article: On-machine fabrication of PCD and WC micro end mills using micro electro discharge machining Journal: International Journal of Mechatronics and Manufacturing Systems (IJMMS) 2014 Vol.7 No.4/5/6 pp.246 - 264 Abstract: Micro electro discharge machining (µ-EDM) process can be used to fabricate micro-milling tools of different geometries from tungsten carbide (WC) and polycrystalline diamond (PCD). The non-contact nature of EDM process makes micro tool fabrication a challenging task while offering the advantage of eliminating tool run out and clamping errors since micro tools fabricated on-machine. The tools are fabricated and used on the same spindle. In this study, a combination of block-EDM and wire electro discharge grinding (WEDG) techniques are used to fabricate micro end mills of different geometries. The influences of EDM process parameters on material erosion rate and surface roughness are examined. The performance of the fabricated micro-tools in ductile mode machining of fused silica has been investigated. It is found that micro end mills can be used to fabricate prototypes of microfluidics chips with acceptable quality. Inderscience Publishers - linking academia, business and industry through research

Title: On-machine fabrication of PCD and WC micro end mills using micro electro discharge machining

Authors: Samad Nadimi Bavil Oliaei; Cem Özdemir; Yiğit Karpat

Addresses: Department of Mechanical Engineering, Bilkent University, 06800 Ankara, Turkey ' Department of Industrial Engineering, Bilkent University, 06800 Ankara, Turkey ' Department of Industrial Engineering, Bilkent University, 06800 Ankara, Turkey; Department of Mechanical Engineering, Bilkent University, 06800 Ankara, Turkey

Abstract: Micro electro discharge machining (µ-EDM) process can be used to fabricate micro-milling tools of different geometries from tungsten carbide (WC) and polycrystalline diamond (PCD). The non-contact nature of EDM process makes micro tool fabrication a challenging task while offering the advantage of eliminating tool run out and clamping errors since micro tools fabricated on-machine. The tools are fabricated and used on the same spindle. In this study, a combination of block-EDM and wire electro discharge grinding (WEDG) techniques are used to fabricate micro end mills of different geometries. The influences of EDM process parameters on material erosion rate and surface roughness are examined. The performance of the fabricated micro-tools in ductile mode machining of fused silica has been investigated. It is found that micro end mills can be used to fabricate prototypes of microfluidics chips with acceptable quality.

Keywords: electrical discharge machining; micromachining; micro milling; end milling; micro EDM; electro-discharge machining; tungsten carbide; WC; polycrystalline diamond; PCD; tool fabrication; micro tools; process parameters; material erosion rate; surface roughness; ductile machining; fused silica; microfluidics.

DOI: 10.1504/IJMMS.2014.067166

International Journal of Mechatronics and Manufacturing Systems, 2014 Vol.7 No.4/5/6, pp.246 - 264

Received: 05 Nov 2013
Accepted: 10 Apr 2014
Published online: 07 Feb 2015 *

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Title: On-machine fabrication of PCD and WC micro end mills using micro electro discharge machining

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