Study of an ultrafine w-EDM technique

• Published in: Journal of micromechanics and microengineering 2009-11, Vol.19 (11), p.115033-115033 (8)
• Main Authors: Chen, Shun-Tong, Yang, Hong-Ye, Du, Chih-Wei
• Format: Article
• Language: English
• Subjects: Applied sciences; Electrical engineering. Electrical power engineering; Electronics; Exact sciences and technology; Instruments, apparatus, components and techniques common to several branches of physics and astronomy; Mechanical engineering. Machine design; Mechanical instruments, equipment and techniques; Microelectronic fabrication (materials and surfaces technology); Micromechanical devices and systems; Physics; Power electronics, power supplies; Precision engineering, watch making; Semiconductor electronics. Microelectronics. Optoelectronics. Solid state devices
• ISSN: 0960-1317; 1361-6439
• DOI: 10.1088/0960-1317/19/11/115033

A precision ultrafine w-EDM (wire electrical discharge machining) technique specifically for machining intricate parts and structures is developed in this paper. A thumb-sized and versatile w-EDM device equipped with a complete control system for wire tension (ultrafine tungsten wire of 13 mum diameter) is designed and employed for the study of ultrafine w-EDM. The tension of the wire electrode is controlled by magnetic repulsive force to steady the wire during machining. Ultrafine wire cutting can be conducted in vertical-, horizontal- or slantwise-wire arrangements. Via some experiments, optimal machining conditions including discharge capacitance, feed rate, wire tension and the appropriate design for the w-EDM device are obtained. Two miniature samples including a micro of Taipei's landmark 101 building and a micro relay are fabricated and the feasibility of the proposed approach is verified. It is confirmed that the ultrafine w-EDM technique using an ultrafine tungsten wire of 13 mum was realized successfully.