Virtual EDM simulator: Three-dimensional geometric simulation of micro-EDM milling processes

• Published in: International journal of machine tools & manufacture Vol. 49; no. 12; pp. 1029 - 1034
• Main Authors: Heo, Segon, Jeong, Young Hun, Min, Byung-Kwon, Lee, Sang Jo
• Format: Journal Article
• Language: English
• Published: Kidlington Elsevier Ltd 01.10.2009; Elsevier
• Subjects: Applied sciences; Exact sciences and technology; Mechanical engineering. Machine design; Micromachining; Precision engineering, watch making; Process simulation; Virtual machining; Z-map; Virtual machining; Z-map; Process simulation; Micromachining; Modeling; Electrical discharge machining; Cavity; Optimal trajectory; Virtual reality; Tool wear; Cutting tool; Simulator; Computer aided design
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2009.07.005

In this paper a three-dimensional geometric simulation method of micro-EDM milling processes is proposed, which introduces a Z-map algorithm to precisely represent the geometries of a machined workpiece and the evolution of the tool shape caused by tool wear during the machining. The micro-EDM milling process is mathematically and geometrically modeled. In order to verify the performance of the developed simulator, an actual square cavity is machined and compared to the simulation result. The developed EDM simulator can be used for tool path generation for tool wear compensation as well as for prediction of tool wear.