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Scale effects and a method for similarity evaluation in micro electrical discharge machining

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Abstract

Electrical discharge machining(EDM) is a promising non-traditional micro machining technology that offers a vast array of applications in the manufacturing industry. However, scale effects occur when machining at the micro-scale, which can make it difficult to predict and optimize the machining performances of micro EDM. A new concept of “scale effects” in micro EDM is proposed, the scale effects can reveal the difference in machining performances between micro EDM and conventional macro EDM. Similarity theory is presented to evaluate the scale effects in micro EDM. Single factor experiments are conducted and the experimental results are analyzed by discussing the similarity difference and similarity precision. The results show that the output results of scale effects in micro EDM do not change linearly with discharge parameters. The values of similarity precision of machining time significantly increase when scaling-down the capacitance or open-circuit voltage. It is indicated that the lower the scale of the discharge parameter, the greater the deviation of non-geometrical similarity degree over geometrical similarity degree, which means that the micro EDM system with lower discharge energy experiences more scale effects. The largest similarity difference is 5.34 while the largest similarity precision can be as high as 114.03. It is suggested that the similarity precision is more effective in reflecting the scale effects and their fluctuation than similarity difference. Consequently, similarity theory is suitable for evaluating the scale effects in micro EDM. This proposed research offers engineering values for optimizing the machining parameters and improving the machining performances of micro EDM.

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Author information

Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Qingyu Liu, Qinhe Zhang, Kan Wang, Guang Zhu, Xiuzhuo Fu & Jianhua Zhang

  2. School of Mechanical and Automotive Engineering, Shandong University, Jinan, 250061, China

    Xiuzhuo Fu

Authors
  1. Qingyu Liu
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  2. Qinhe Zhang
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  3. Kan Wang
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  4. Guang Zhu
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  5. Xiuzhuo Fu
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  6. Jianhua Zhang
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Corresponding author

Correspondence to Qinhe Zhang.

Additional information

Supported by National Natural Science Foundation of China(Grant No. 51375274), and China Postdoctoral Science Foundation(Grant No. 2014M561920)

LIU Qingyu, born in 1989, is currently a PhD candidate at Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, China. He received his bachelor degree from Qingdao Technological University, China, in 2011. His main research interests include macro and micro EDM technique and equipment.

ZHANG Qinhe, born in 1968, is currently a professor and a PhD candidate supervisor at Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, China. He received his PhD degree on mechanical and automation engineering in Shandong University, China, in 2003. His research interests include non-traditional machining technology and equipment, micro machining, precision machining.

WANG Kan, born in 1990, is currently a PhD candidate at Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, China. His research interests include macro and micro EDM technique and equipment.

ZHU Guang, born in 1991, is currently a master candidate at Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, China. His main research interests include macro and micro EDM technique and equipment.

FU Xiuzhuo, born in 1978, is currently a lecturer at Shandong Polytechnic University, China. He received his PhD degree from Shandong University, China, in 2011. His research interests include non-traditional machining technology and equipment.

ZHANG Jianhua, born in 1964, is currently a professor and a PhD candidate supervisor at Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, Shandong University, China. His main research interests include high-efficiency, precision machining technology and numerical control equipment.

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Liu, Q., Zhang, Q., Wang, K. et al. Scale effects and a method for similarity evaluation in micro electrical discharge machining. Chin. J. Mech. Eng. 29, 1193–1199 (2016). https://doi.org/10.3901/CJME.2016.0622.077

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  • DOI: https://doi.org/10.3901/CJME.2016.0622.077

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