Orbital electrode actuation to improve efficiency of drilling micro-holes by micro-EDM

This paper presents a novel machining technique for micro-EDM that actuates the EDM electrode on an orbital trajectory that is created by a 2-axis flexural micro-EDM head with a range of ±100 μm in both x- and y-directions. The orbital motion with its adjustable radius decouples the size of the hole to be drilled from the size of the electrode, allowing a range of hole sizes to be drilled. The orbital motion of the electrode increases the hole diameter proportional to the orbital radius, thereby creating a larger gap between the work piece and the electrode, which promotes increased flushing. For holes with large depth to diameter ratios, the increased flushing reduces electrode wear, creates a better surface finish, and eliminates the exponential reduction in material removal rates typical for EDM drilling.