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Micro Electric Discharge Machining
Meaning
Non traditional machining techniques employ electrical discharges to erode conductive materials with micron level accuracy. Utilizing micro electric discharge machining enables the creation of features smaller than 100 micrometers in hardened alloys. This process operates without physical contact between the tool electrode and the workpiece.
Removal Mechanism
Rapid sparks occurring in a dielectric fluid melt and vaporize small amounts of material from the target surface. During micro electric discharge machining, the spark gap is maintained by a sensitive servo system to prevent short circuits. Each pulse removes a tiny crater of metal.
Material removal rate depends on the frequency and energy of the electrical pulses. High frequency discharges produce the smoothest surface finishes.
Tooling Application
Microscopic holes and complex cavities in fuel injectors or medical devices require this level of precision. Because micro electric discharge machining does not exert mechanical force, it is ideal for thin or fragile parts. Brass or tungsten wires often serve as the electrode material.
Surface Integrity
Thermal effects of the sparks create a heat affected zone on the finished part. While micro electric discharge machining produces a fine finish, the resulting recast layer may require secondary polishing for high stress applications. Controlled pulse timing minimizes this effect.
The choice of dielectric fluid influences the cooling rate and the final metallurgical properties of the surface.