Research Papers

Optimization of Micropencil Grinding Tools Via Electrical Discharge Machining

[+] Author and Article Information
Peter A. Arrabiyeh

Institute for Manufacturing Technology and
Production System,
TUK University of Kaiserslautern,
P.O. Box 3049,
Kaiserslautern 67653, Germany
e-mail: Peter.Arrabiyeh@mv.uni-kl.de

Maximilian Dethloff

Institute for Manufacturing Technology and
Production System,
TUK University of Kaiserslautern,
P.O. Box 3049,
Kaiserslautern 67653, Germany
e-mail: maxdethloff@gmail.com

Christopher Müller

Institute for Manufacturing Technology and
Production System,
TUK University of Kaiserslautern,
P.O. Box 3049,
Kaiserslautern 67653, Germany
e-mail: mueller.christopher@mailbox.org

Benjamin Kirsch

Institute for Manufacturing Technology and
Production System,
TUK University of Kaiserslautern,
P.O. Box 3049,
Kaiserslautern 67653, Germany
e-mail: Benjamin.Kirsch@mv.uni-kl.de

Jan C. Aurich

Institute for Manufacturing Technology and
Production System,
TUK University of Kaiserslautern,
P.O. Box 3049,
Kaiserslautern 67653, Germany
e-mail: FBK@mv.uni-kl.de

1Corresponding author.

Manuscript received June 29, 2018; final manuscript received November 21, 2018; published online January 17, 2019. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 141(3), 031005 (Jan 17, 2019) (9 pages) Paper No: MANU-18-1498; doi: 10.1115/1.4042110 History: Received June 29, 2018; Revised November 21, 2018

Micropencil grinding tools (MPGTs) are micromachining tools that use superabrasives like diamond and cubic boron nitride (cBN) grits to manufacture complex microstructures in a broad range of hard and brittle materials. MPGTs suffer from a rather low tool life, when compared to other more established microprocessing methods. It was documented that when used on hardened steel workpieces, MPGTs suffer from a large amount of adhesions, mostly located at the pivot point of the tool. These adhesions lead to the clogging of the abrasive layer and ultimately in tool failure. Another problem this machining process suffers from is the formation of substructures (smaller channels inside the microchannels). The pivot is usually less prone to abrasive wear, has higher protrusion, and is therefore responsible for the deepest substructures. These substructures can easily take up half the depth of cut, obstructing the function of machined microchannels—it is one of the major flaws of this micromachining process. A micro-electrical discharge machining method (μEDM) can solve these issues by manufacturing a cavity at the pivot of these tools. A novel method that uses measurement probes to position the substrate above the μEDM electrode is implemented and a parameter study to determine the cavity manufacturing parameters is conducted for substrates with diameters < 40 μm. The goal is to demonstrate the first ever complete and reliable manufacturing process for MPGTs with a cavity and to demonstrate the advantages they provide in a machining process when compared to regular MPGTs.

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Grahic Jump Location
Fig. 1

Micropencil grinding tool with grit size 3–6 μm and a microstructure machined with this MPGT

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Fig. 2

Manufacturing process for MPGTs with solution components [9]

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Fig. 3

Principle of μEDM according to Ref. [32]

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Fig. 4

Micro-electrical discharge machining system

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Fig. 5

Micro-electrode forms

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Fig. 6

(a) Pointy micro-electrode form preprocess and (b) micro-electrode post process

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Fig. 7

Micro-electrical discharge machining parameter schematic

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Fig. 8

Diagram showing influence of (a) voltage on spark gap (b) pulse duration on spark gap

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Fig. 9

Substrate with cavity

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Fig. 10

Ultra precision four-axes machine tool [6]

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Fig. 11

Micropencil grinding tools with cavities

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Fig. 12

Microgrinding process

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Fig. 13

Cutouts of microstructures and the MPGTs used to machine them: (a) process with regular MPGT, (b) process with inclined MPGT (2 deg), and (c) process with optimized MPGT

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Fig. 14

(a) Optimized MPGT durability test and (b) microstructure in the shape of a triangle with MPGT postmachining



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