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Electric metal-cutting. --- Electric discharge machining --- Electric machining --- Electric spark machining --- Spark-erosion machining --- Metal-cutting

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This work describes an experimental investigation with the aim to evaluate and establish wire spark erosion machining (WSEM) as a viable alternative for high quality miniature gear manufacturing. External spur type miniature brass (ASTM 858) gears with 12 teeth, 9.8 mm outside diameter and 5 mm face width were manufactured by WSEM. The research work was accomplished in four distinct experimental stages viz., preliminary, pilot, main and confirmation. The aim, scope and findings of each stage are progressively presented and discussed. In essence, the investigation found that it was possible to manufacture miniature gears to high quality by using WSEM. Gears up to DIN 5 quality with a good surface finish (1.2 µm average roughness) and satisfactory surface integrity were achieved. The results suggest that WSEM should be considered a viable alternative to conventional miniature gear manufacturing techniques and that in some instances it may even be superior. This work will prove useful to researchers and professionals in the field of miniature and micro-scale manufacturing and machining.

Electric metal-cutting. --- Gearing --- Manufacture. --- Electric discharge machining --- Electric machining --- Electric spark machining --- Spark-erosion machining --- Gear-cutting machines --- Metal-cutting --- Manufactures. --- Engineering. --- Engineering design. --- Manufacturing, Machines, Tools, Processes. --- Machinery and Machine Elements. --- Engineering Design. --- Design, Engineering --- Engineering --- Industrial design --- Strains and stresses --- Construction --- Industrial arts --- Technology --- Manufactured goods --- Manufactured products --- Products --- Products, Manufactured --- Commercial products --- Manufacturing industries --- Design --- Machinery. --- Machinery --- Machines --- Manufactures --- Power (Mechanics) --- Mechanical engineering --- Motors --- Power transmission --- Curious devices

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Micro electrical discharge machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Many industrial domains exploit this technology to fabricate highly demanding components, such as high-aspect-ratio micro holes for fuel injectors, high-precision molds, and biomedical parts.Moreover, the continuous trend towards miniaturization and high precision functional components boosted the development of control strategies and optimization methodologies specifically suited to address the challenges in micro- and nano-scale fabrication.This Special Issue showcases 12 research papers and a review article focusing on novel methodological developments on several aspects of micro electrical discharge machining: machinability studies of hard materials (TiNi shape memory alloys, Si3N4–TiN ceramic composite, ZrB2-based ceramics reinforced with SiC fibers and whiskers, tungsten-cemented carbide, Ti-6Al-4V alloy, duplex stainless steel, and cubic boron nitride), process optimization adopting different dielectrics or electrodes, characterization of mechanical performance of processed surface, process analysis, and optimization via discharge pulse-type discrimination, hybrid processes, fabrication of molds for inflatable soft microactuators, and implementation of low-cost desktop micro-EDM system.

Technology: general issues --- electrodischarge micromachining --- drilling --- cubic boron nitride --- foil queue microelectrode --- micro-EDM --- step effect --- tapered structure --- wire electrical discharge grinding (WEDG) --- micromoulding --- soft microrobotics --- electrical discharge machining (EDM) --- Tungsten cemented carbide (WC-Co) --- desktop micro-electrical discharge machining (micro-EDM) system --- cut-side micro-tool --- micro-holes --- EDM --- SR --- TWR --- PMEDM --- MRR --- electro-discharge treatment --- Ti-6Al-4V --- MWCNTs --- surface characterization --- wear resistance --- corrosion resistance --- composite 3D microelectrode --- diffusion bonding --- step --- 3D microstructure --- material processing --- DSS-2205 alloy --- electric-discharge machining --- surface integrity --- surface wettability --- ceramic composite --- micro-EDM milling --- pulse discrimination --- Micro-electro-discharge machining (μEDM) --- liquid-metal electrode --- Galinstan --- Zirconium Boride --- silicon carbide fibers --- silicon carbide whiskers --- advanced material --- TiNi shape memory alloy --- TiC powder --- surface modification --- microhardness --- electrochemical discharge machining --- laser machining --- glass --- micro-groove --- n/a

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Micro electrical discharge machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Many industrial domains exploit this technology to fabricate highly demanding components, such as high-aspect-ratio micro holes for fuel injectors, high-precision molds, and biomedical parts.Moreover, the continuous trend towards miniaturization and high precision functional components boosted the development of control strategies and optimization methodologies specifically suited to address the challenges in micro- and nano-scale fabrication.This Special Issue showcases 12 research papers and a review article focusing on novel methodological developments on several aspects of micro electrical discharge machining: machinability studies of hard materials (TiNi shape memory alloys, Si3N4–TiN ceramic composite, ZrB2-based ceramics reinforced with SiC fibers and whiskers, tungsten-cemented carbide, Ti-6Al-4V alloy, duplex stainless steel, and cubic boron nitride), process optimization adopting different dielectrics or electrodes, characterization of mechanical performance of processed surface, process analysis, and optimization via discharge pulse-type discrimination, hybrid processes, fabrication of molds for inflatable soft microactuators, and implementation of low-cost desktop micro-EDM system.

electrodischarge micromachining --- drilling --- cubic boron nitride --- foil queue microelectrode --- micro-EDM --- step effect --- tapered structure --- wire electrical discharge grinding (WEDG) --- micromoulding --- soft microrobotics --- electrical discharge machining (EDM) --- Tungsten cemented carbide (WC-Co) --- desktop micro-electrical discharge machining (micro-EDM) system --- cut-side micro-tool --- micro-holes --- EDM --- SR --- TWR --- PMEDM --- MRR --- electro-discharge treatment --- Ti-6Al-4V --- MWCNTs --- surface characterization --- wear resistance --- corrosion resistance --- composite 3D microelectrode --- diffusion bonding --- step --- 3D microstructure --- material processing --- DSS-2205 alloy --- electric-discharge machining --- surface integrity --- surface wettability --- ceramic composite --- micro-EDM milling --- pulse discrimination --- Micro-electro-discharge machining (μEDM) --- liquid-metal electrode --- Galinstan --- Zirconium Boride --- silicon carbide fibers --- silicon carbide whiskers --- advanced material --- TiNi shape memory alloy --- TiC powder --- surface modification --- microhardness --- electrochemical discharge machining --- laser machining --- glass --- micro-groove --- n/a

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• Reference Manager
• EndNote
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Micro electrical discharge machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Many industrial domains exploit this technology to fabricate highly demanding components, such as high-aspect-ratio micro holes for fuel injectors, high-precision molds, and biomedical parts.Moreover, the continuous trend towards miniaturization and high precision functional components boosted the development of control strategies and optimization methodologies specifically suited to address the challenges in micro- and nano-scale fabrication.This Special Issue showcases 12 research papers and a review article focusing on novel methodological developments on several aspects of micro electrical discharge machining: machinability studies of hard materials (TiNi shape memory alloys, Si3N4–TiN ceramic composite, ZrB2-based ceramics reinforced with SiC fibers and whiskers, tungsten-cemented carbide, Ti-6Al-4V alloy, duplex stainless steel, and cubic boron nitride), process optimization adopting different dielectrics or electrodes, characterization of mechanical performance of processed surface, process analysis, and optimization via discharge pulse-type discrimination, hybrid processes, fabrication of molds for inflatable soft microactuators, and implementation of low-cost desktop micro-EDM system.

Technology: general issues --- electrodischarge micromachining --- drilling --- cubic boron nitride --- foil queue microelectrode --- micro-EDM --- step effect --- tapered structure --- wire electrical discharge grinding (WEDG) --- micromoulding --- soft microrobotics --- electrical discharge machining (EDM) --- Tungsten cemented carbide (WC-Co) --- desktop micro-electrical discharge machining (micro-EDM) system --- cut-side micro-tool --- micro-holes --- EDM --- SR --- TWR --- PMEDM --- MRR --- electro-discharge treatment --- Ti-6Al-4V --- MWCNTs --- surface characterization --- wear resistance --- corrosion resistance --- composite 3D microelectrode --- diffusion bonding --- step --- 3D microstructure --- material processing --- DSS-2205 alloy --- electric-discharge machining --- surface integrity --- surface wettability --- ceramic composite --- micro-EDM milling --- pulse discrimination --- Micro-electro-discharge machining (μEDM) --- liquid-metal electrode --- Galinstan --- Zirconium Boride --- silicon carbide fibers --- silicon carbide whiskers --- advanced material --- TiNi shape memory alloy --- TiC powder --- surface modification --- microhardness --- electrochemical discharge machining --- laser machining --- glass --- micro-groove --- electrodischarge micromachining --- drilling --- cubic boron nitride --- foil queue microelectrode --- micro-EDM --- step effect --- tapered structure --- wire electrical discharge grinding (WEDG) --- micromoulding --- soft microrobotics --- electrical discharge machining (EDM) --- Tungsten cemented carbide (WC-Co) --- desktop micro-electrical discharge machining (micro-EDM) system --- cut-side micro-tool --- micro-holes --- EDM --- SR --- TWR --- PMEDM --- MRR --- electro-discharge treatment --- Ti-6Al-4V --- MWCNTs --- surface characterization --- wear resistance --- corrosion resistance --- composite 3D microelectrode --- diffusion bonding --- step --- 3D microstructure --- material processing --- DSS-2205 alloy --- electric-discharge machining --- surface integrity --- surface wettability --- ceramic composite --- micro-EDM milling --- pulse discrimination --- Micro-electro-discharge machining (μEDM) --- liquid-metal electrode --- Galinstan --- Zirconium Boride --- silicon carbide fibers --- silicon carbide whiskers --- advanced material --- TiNi shape memory alloy --- TiC powder --- surface modification --- microhardness --- electrochemical discharge machining --- laser machining --- glass --- micro-groove