Simultaneous Machining of Polygonal Microelectrode and Microholes Using Tandem EDM Mechanism

In this paper, we propose the simultaneous machining of a polygonal microelectrode and microholes using a tandem electrical discharge machining (EDM) mechanism. Two types of power sources for forming the polygonal pillar electrode and hole machining were installed on the same machine. A mask plate with the target shape is used to form the electrode. Planar motion was applied to the mask plate, and a polygonal micropillar electrode was produced by reducing operation. In this process, the low wear condition of the mask plate and the high wear condition of the electrode were chosen. Zinc alloy, which is easy to form by EDM, was used for the electrode material. After the electrode was formed, polygonal microholes were drilled into a tungsten plate using this electrode. Microhole machining with a zinc alloy electrode resulted in a removal rate that was higher than that with a copper electrode of the same shape. To perform simultaneous machining of a microelectrode and microholes, a tandem structure mechanism was constructed. Continuous polygonal microhole machining was attained by applying the tandem EDM mechanism under the appropriate conditions.