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ABSTRACT
Micro EDM is a tool-based micromachining process for fabricating micro-features on metallic surfaces. The existing microtool fabrication techniques are complex and require an additional setup, which increases the cost. This study proposed a simple and cost-effective method called sheet electrical discharge grinding (sheet-EDG). A 500 μm diameter tungsten carbide rod was radially fed and later reciprocated along a 100-μm-thick brass sheet to fabricate high aspect ratio (AR) microtools without any noticeable taper. The effects of process parameters, such as optimal tool path, radial infeed positions, sheet thickness, sheet-EDG parameter, radial infeed per pass, radial infeed rate, and traverse feed rate were investigated and discussed. Further, two microtools with average diameter of 28 μm and 23 μm, having AR of more than 50 and 100, respectively, were fabricated. Finally, different shaped-microtools were fabricated based on modified tool paths. The results demonstrate that sheet-EDG technique can fabricate high AR microtools with different end shapes.
Disclosure statement
No potential conflict of interest was reported by the author(s).