Simulation And Experimental Study On Block Electrode Discharge Grinding Of Micro Electrodes

Micro electrodes are widely used in the Electrical Discharge Machining of micro holes and micro three-dimensional structures,so the preparation of microelectrodes has always been one of the difficulties and hot spots in the field of EDM.At present,the main machining method of micro electrodes is Block Electrode Discharge Grinding(BEDG).However,because the erosion mechanism of micro electrodes is not clear in the process of BEDG of micro electrodes,which affects the application and rapid development of machining technology of Electrical Discharge Machining.Therefore,it is necessary to study the machining mechanism of micro electrodes in the process of BEDG of micro electrodes.In this paper,from the perspective of simulation of temperature field,stress field and machining experiment,the numerical simulation of the erosion process of micro electrodes is carried out to reveal the machining mechanism of the micro electrodes in the BEDG,and experiments are carried out to verify the simulation results.This study will provide theoretical basis and technical support for the research of the BEDG of micro electrodes.Firstly,the simulation model of temperature field of single pulse discharge in the process of BEDG of micro electrodes is established.The temperature field distribution and crater shape under single pulse discharge are numerically simulated to analyze the influence of pulse width on the maximum temperature and crater volume of the micro electrodes.The rationality of the simulation is verified by experiments of BEDG of micro electrodes.Secondly,the simulation model of temperature field of continuous pulse discharge in the process of BEDG of micro electrodes is established.The distribution of temperature field and the volume of craters on the surface of micro electrodes under continuous pulse discharge are simulated.The dynamic formation process of the craters on the surface of the micro electrode,the change rule of the volume of craters and the maximum discharge temperature,and the influence rule of the pulse width on the size and shape of the craters on the surface of the micro electrode are studied to reveal the machining mechanism of the micro electrodes in the BEDG.And the simulation results are verified by the experiment of BEDG of micro electrodes.Finally,the preparation of micro electrodes is carried out by the method of BEDG.And the EDM experiments of micro-holes under different peak currents,different pulse widths and different materials are conducted to analyze the influence of peak current,pulse width and materials on the micro-hole diameter,processing efficiency and electrode loss.