Numerical modelling and experimental investigations to predict the tool wear of copper electrodes during µ-EDM process

IF 4.6 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology Pub Date : 2024-10-04 DOI:10.1016/j.cirpj.2024.09.011

S. Arun, M. Manikandan, Jino Joshy, Basil Kuriachen, Jose Mathew

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引用次数: 0

Abstract

The micro electrical discharge machining (µ-EDM) process is one of the most widely used techniques to produce miniaturized components in micro-electro mechanical system (MEMS) applications due to its inherent advantages. This work investigates the wear phenomena and the morphology of the copper electrodes during the micro-die sinking process. A numerical model of a single spark is developed assuming the Gaussian distribution of heat flux to estimate the crater dimensions formed in the copper tool electrode (tool wear) used as a result of electric discharge. The crater dimension attained from the ABAQUS finite element model is validated with experimental results using a single spark test setup. Moreover, the effect of input parameters namely capacitance and voltage on the electrode wear rate and surface roughness is also studied. The crater dimensions from the single discharge study are used to formulate the wear model for different possibilities of crater distribution, such as non-overlapping craters, craters with less than 30 % overlap, and 50 % overlap. The electrode wear rate (EWR) also displayed a decline from 20.4 % to 11.6 % and further to 8 % when the overlap was permitted up to 30 % and up to 50 % for the wear model respectively. The developed model results are further compared with experimental results in terms of the electrode wear rate and depth of erosion and the deviations are found to be 20.33 % and 20.55 % respectively

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预测 µ-EDM 过程中铜电极工具磨损的数值建模和实验研究

微型放电加工（µ-EDM）工艺因其固有的优势，成为微型机电系统（MEMS）应用中生产微型元件最广泛使用的技术之一。这项工作研究了微模沉积过程中铜电极的磨损现象和形态。假设热通量呈高斯分布，建立了一个单火花数值模型，以估算放电在铜工具电极上形成的凹坑尺寸（工具磨损）。ABAQUS 有限元模型得出的凹坑尺寸与使用单火花测试装置的实验结果进行了验证。此外，还研究了输入参数（电容和电压）对电极磨损率和表面粗糙度的影响。单次放电研究得出的陨石坑尺寸被用于制定不同陨石坑分布可能性的磨损模型，如无重叠陨石坑、重叠率小于 30% 的陨石坑和重叠率为 50% 的陨石坑。当磨损模型允许的重叠率分别达到 30% 和 50%时，电极磨损率 (EWR) 也分别从 20.4% 下降到 11.6%和 8%。就电极磨损率和侵蚀深度而言，所开发模型的结果与实验结果进行了进一步比较，发现偏差分别为 20.33 % 和 20.55 %。

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来源期刊

CIRP Journal of Manufacturing Science and Technology Engineering-Industrial and Manufacturing Engineering

CiteScore

9.10

自引率

6.20%

发文量

166

审稿时长

63 days

期刊介绍： The CIRP Journal of Manufacturing Science and Technology (CIRP-JMST) publishes fundamental papers on manufacturing processes, production equipment and automation, product design, manufacturing systems and production organisations up to the level of the production networks, including all the related technical, human and economic factors. Preference is given to contributions describing research results whose feasibility has been demonstrated either in a laboratory or in the industrial praxis. Case studies and review papers on specific issues in manufacturing science and technology are equally encouraged.