Servo Scanning 3D Micro Electro Discharge Machining: Principles and Methods for Machining 3D Microstructures

✍ Scribed by Hao Tong, Yong Li

• Publisher: Springer
• Year: 2022
• Tongue: English
• Leaves: 237
• Edition: 1st ed. 2023
• Category: Library

✦ Synopsis

This book provides the systematic knowledge of a novel process of servo scanning 3D micro-electro-discharge machining (SS-3D micro-EDM), covering principles, methods, technologies, and optimization for machining 3D microstructures of conductive materials. The content emphasizes the systematic knowledge as well as the frontier research progress of SS-3D micro-EDM, allowing it to be used as a reference handbook for planning the whole machining process of 3D microstructures, for designing machining systems or machine tools, and even for understanding the ideas of innovative processes. The processes and the machine tools of SS-3D micro-EDM have promising applications in multi-fields for machining micro-devices or microstructures made of melt and metal alloy materials. The included methods and technologies are verified by testing and machining experiments. Thus, this book presents many machining examples, including the experimental parameters, conditions, and systems. These help the readers understand the concepts, theories, and methods easily and provide practical operation guidance for engineering applications in industrial machining processes and machine tools.

✦ Table of Contents

Preface
Acknowledgements
Contents
About the Authors
Abbreviations
1 Basic Principle
1.1 Introduction
1.2 Basic Principles of Servo Scanning 3D Micro EDM Process
1.3 Feasibility Verification of Process Principle
1.4 Summary
References
2 3D CAD/CAM System
2.1 Introduction
2.2 System Design
2.2.1 Planning of Path Type and Path Span
2.2.2 Post Processing of NC Codes
2.2.3 Implementation Example of CAD/CAM System
2.3 Control Strategy of CAM Process
2.4 Summary
References
3 Design and Test of Pulsed Power Supply
3.1 Introduction
3.2 Design and Test of Pulsed Power Supply with Multi-Functions
3.2.1 Logic Circuit Design for Generating High Frequency Pulses
3.2.2 High-Speed Isolated Driving Circuit of MOSFET Switch
3.2.3 Performance Test of Pulsed Power Supply
3.2.4 Detection Circuit of Discharge Gap State
3.3 Pulsed Power Supply with Ns-Pulsewidth Based on Triode Avalanche Principle
3.3.1 Basic Principle of Ns-Pulsewidth Pulsed Power Supply
3.3.2 Design and Performance Tests of Basic Circuit of Ns-Pulsewidth Pulsed Power Supply
3.3.3 Design and Performance Tests of Cascaded Circuit with Two Triodes for Improving Ns-Pulsewidth Pulsed Power Supply
3.3.4 Experimental Verification of Ns-Pulsewidth Pulsed Power Supply with Cascaded Circuit
3.4 Summary
References
4 Servo Control of Micro Discharge Gap
4.1 Introduction
4.2 Servo Control Characteristics of Micro Discharge Gap
4.2.1 Experimental System and Method
4.2.2 Experimental Results and Analysis
4.2.3 Experimental Verification with High Response Frequency Spindle
4.3 Threshold Control and Optimization Method
4.3.1 Optimization Constraint of Servo Control Parameters
4.3.2 Matching Scanning Speed with Servo Speed of Tool Electrode
4.3.3 Experiments of Optimization Verification in SS-3D Micro EDM
4.4 Self-Adaptive Fuzzy Control Method with Formulary Rule
4.4.1 Control Strategy and Design of Self-Adaptive Fuzzy Controller with a Formulary Rule
4.4.2 Self-Adaptive Fast Convergence Algorithms
4.4.3 Experimental Verification of Self-Adaptive Fuzzy Control Method in SS-3D Micro EDM
4.5 Summary
References
5 Precision Fabrication and Measurement of Micro Tool Electrode
5.1 Introduction
5.2 Mechanism of Wire Electro Discharge Grinding (WEDG)
5.3 Tangential-Feed WEDG Method and Hybrid Process
5.3.1 Principle and Analysis of TF-WEDG
5.3.2 Hybrid Machining Process of Micro Electrode
5.3.3 Experimental Results and Discussion
5.4 On-Machine Fabrication Process of Flat Micro Tool Electrode
5.4.1 Principle of On-Machine Fabrication for Flat Micro Tool Electrodes
5.4.2 Machining Experiments of Flat Electrodes and Array Micro Grooves
5.5 On-Machine Measurement Method of Intersecting Point Electric Contact
5.6 Summary
References
6 Effect of Process Parameters
6.1 Introduction
6.2 Effect of Electric Parameters on Machining Performance
6.2.1 Effect of Peak Current and Pulse Duration
6.2.2 Effect of Machining Polarity
6.3 Effect of Scanning Paths on Machining Performance
6.3.1 Effect of Path Type
6.3.2 Effect of Path Span
6.4 Effect of Scanning Speed on Machining Performance
6.5 Machining a Typical 3D Micro Structure
6.6 Summary
References
7 Vibration-Assisted SS-3D Micro EDM
7.1 Introduction
7.2 Method and Experimental System
7.3 Fundamental Machining Experiments
7.4 Establishment and Analysis of Machining Process Model
7.5 Machining Experiments for 3D Micro Cavities
7.6 Summary
References
8 SS-3D Micro EDM Based on Macro/Micro-Dual-Feed Spindle
8.1 Introduction
8.2 Method and Experimental System
8.3 Control and Performance Test
8.3.1 Control of Macro/Micro Dual-Feed Spindle
8.3.2 Performance Test of Macro/Micro Dual-Feed Spindle
8.4 Application Experiments
8.4.1 Fundamental Machining Experiments
8.4.2 Machining Experiments of 3D Micro Microstructures
8.5 Summary
References
9 Algorithms to Reduce Depth Errors
9.1 Introduction
9.2 Analysis of Machined-Depth Error and Surface Unevenness
9.3 Illumination of Proposed Algorithms
9.3.1 S-Curve Accelerating Algorithm (SCAA)
9.3.2 Layer Depth Constrained Algorithm (LDCA)
9.4 Implementation Process and Control Strategy of Algorithms
9.5 Experimental Verification of Algorithms
9.5.1 Basic Machining Experiments
9.5.2 Machining Experiments for Typical 3D Micro Cavities
9.6 Summary
References
10 On-Machine Process of Rough-And-Finishing SS-3D Micro EDM
10.1 Introduction
10.2 Rough and Finishing Process of SS-3D Micro EDM
10.3 Strategy of 3D-Model Boundaries
10.4 Machining Experiments of 3D Micro Cavities
10.4.1 Experimental Method and System
10.4.2 Experimental Results
10.5 Summary
References
11 Array SS-3D Micro EDM by Using Array Tool Electrodes
11.1 Introduction
11.2 Processing Method of Array SS-3D Micro EDM
11.3 Array SS-3D Micro EDM by Using Off-Line Fabricated Array Micro Tool Electrodes
11.3.1 Off-Line Preparation of Array Micro Tool Electrodes
11.3.2 Machining Experiments of Array Micro Cavities
11.3.3 Processing Analysis with Off-Line Fabricated Array Micro Electrodes
11.4 Array SS-3D Micro EDM by Using On-Machine Fabricated Array Micro Electrodes
11.4.1 Processing Method with On-Machine Fabrication of Array Tool Electrodes
11.4.2 On-Machine Fabrication of Array Tool Electrodes
11.4.3 Machining Experiments of Array Micro Cavities
11.5 Summary
References
12 Hybrid Process of SS-3D Micro EDM and Scanning 3D Micro ECM
12.1 Introduction
12.2 Hybrid Process of SS-3D Micro EDM and Scanning 3D Micro ECM
12.3 Experimental System and Processing Strategy
12.4 Processing Experiments and Results Analysis
12.4.1 Hybrid Process Experiment for Square Cavity
12.4.2 Hybrid Process Experiment for Micro Spherical Crown Cavity
12.4.3 Analysis of Experimental Results for Hybrid Process
12.5 Summary
References
13 SS-3D Micro EDM Applied in Machining Pierced Micro Structures of TiNi Alloy Tube
13.1 Introduction
13.2 Processing Methods and Experimental System of Four-Axis SS-3D Micro EDM
13.2.1 Processing Methods
13.2.2 Experimental System and Workpiece Clamping Adjustment
13.3 NC Codes Generation and Optimization of Servo Scanning Paths for Complex Pierced Micro Driving Structures
13.3.1 Machining Experiments of Typical Driving Structures
13.4 Summary
References
14 Discussion and Prospect