Simultaneous Processing Method for Micro-Rods and Holes Using EDM

Abstract

This paper describes a new method for micro-EDM drilling which utilizes the wear of rod electrodes. With this method, a pair of micro rod and micro hole can be machined in a single process, while with conventional methods, the micro rod electrode needs to be formed before machining the micro hole. Processing conditions were optimized for the new method to obtain higher aspect ratio for the micro rods. Results of experiments also showed the following: 1) This method can be applied to AISI1045, AISI304 and Kovar and any electrode diameter size. 2) From the second process, if machining many holes using the same electrode, the electrode shape can be regenerated with excellent repeatability and holes processed efficiently. 3) The influence of carbon adhering to the tip region of the rod electrode is large, which is why the rod electrode becomes needle sharp.