Experimental study on the microelectrodes fabrication using low speed wire electrical discharge turning (LS-WEDT) combined with multiple cutting strategy

This paper aims at giving an insight into the fabrication of ultra-small microelectrodes and micro-cutting tools using the low speed wire electrical discharge turning (LS-WEDT). The multiple cutting strategy divides the microelectrode machining process into rough cut (RC), semi-finishing trim cut (TC) and finishing trim cut (FTC). Experimental results indicated that the breaking and bending microelectrodes are caused primarily by the improper selection of flushing pressure, peak current and open circuit voltage in FTC. The cylindrical microelectrode of 58 μm in diameter is successfully fabricated with good surface quality and high machining accuracy. More importantly, the LS-WEDT method can be used to manufacture the microelectrodes and micro-cutting tools with different micro structures by combining with the numerical control technology. The D-shaped cutting tool of 65 μm in diameter and the three spiral micro cutting tool are firstly and successfully manufactured by LS-WEDT method.