Complex Rotary Structures Machined by Micro-WEDM☆

Abstract In this paper, a method of complex rotary structures machined by micro wire electrical discharge machining (micro-WEDM) is presented. A high-speed rotating spindle has been designed and installed to the self-developed precise micro-WEDM equipment with two axis to enable the processing of complex rotary structures. The feasibility of the device for machining rotary structures is verified by performing many preliminary experiments. Meanwhile, the effects of open voltage and revolving speed on material removing rate (MRR) and average surface roughness (Ra) are investigated. A multiple cutting method for micro ball-ended probe using micro-WEDM is proposed, which includes rough machining with high machining parameters and finish machining with low machining parameters. What's more, the reuse of the reciprocated fine wire electrode with 30 μm diameter was realized in both process steps. Ultimately, a typical experimental sample, micro ball-ended probe with 97.6 μm in diameter and 0.7 μm in Ra was successfully fabricated.