• Transactions of the Korean Society of Machine Tool Engineers
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• v.14 no.5
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• pp.13-20
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• 2005

Micro EDM process is generally used for machining microholes, cavities, and three dimensional shapes. For machining micro structures, first of all, micro tool electrode is indispensable and WEDG system is proposed for tool fabrication method. When using WEDG, its machining characteristics are highly affected by many EDM parameters such as applied voltage, current, rotation speed, capacitance, and pulse duration. Therefore, the design of experiment is introduced to fully understand the effect of the EDM parameters on machining tool electrode. And an attempt has been made to develop the mathematical model for predicting the size of the tool electrode by calculating spark distance. The suggested model was verified with experiment and predicted working gap distance is in good accord with the measured value.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.624-627
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• 2002

A study on machining electrode for LEO(Light Emitted Diode) mold with shaped end-mill is presented. The electrode machining by shaped end-mill has been used for maximizing the productivity in manufacture of semiconductor mold. However, it has not been researched systematically for many difficulties such as the making of shaped end-mill, generation of tool path due to distinctive tool geometry, and so on. Tool path is generated on the shaped end-mill geometry and cutting force to provide accurate and efficient machining of electrode. The verification program can drive enhancement of productivity, selecting cutting conditions from experiment function of cutting force. Also, compensation of tooting and machina error can make the electrode accurate by modifying tool path. Therefore, the research on machining with shaped end-mill can contribute to enhancement of accuracy and productivity in building semiconductor mold.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.5
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• pp.496-501
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• 2009

In micro electrochemical machining(micro-ECM), it is important to measure and control the potential of a tool electrode and a workpiece electrode because electrochemical reaction rate depends on the potential of the electrodes. When the electrode potential was measured against a reference electrode, the error of measured electrode potential could be minimized by proper tool electrode design. In this paper, multi-function electrodes consisting of a tool electrode and a reference electrode was fabricated by micro fabrication techniques. The machining conditions in micro-ECM using multi-function electrodes, such as pulse voltage parameters and electrode potential, were investigated.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.27-33
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• 2000

This paper presents a method for determining machining parameters in 3-dimentional electrical discharge machining(EDM). The parameters are the peak value of currents, the pulse-on time, and the pulse-off time. It is known that they influence the performance of EDM more than the other else. The parameters are determined from the discharge area between a tool electrode and a work piece. The discharge area is directly influenced by the geometry of a tool surface and the tool discharge position. The discharge area on a tool discharge position is calculated from intersection curves between the tool surface and a horizontal plane. The grid search method is applied to determine the intersection curves. An example is introduced to show that the machining parameters are obtained from the surface geometry of a tool electrode.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.5
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• pp.58-64
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• 2000

This paper proposes a method for determining optimal EDM parameters based on discharge area from the physical model of a tool electrode. Main parameters, which affect the EDM performance, are peak value of currents, pulse-on time, and pulse-off time. Such parameters are closely dependent on the discharge area in EDM process. In this paper the discharge area is estimated from the CMM scanning data to the tool electrode. The method is very useful when any geometric information to the tool electrode is not provided from tool modeler or producer. The method consists of following four steps. First a triangulation mesh is constructed from the CMM data. Secondly, the z-map is modeled from the triangulated mesh. Thirdly, the discharge area is estimated from intersection between the z-map model and a z-height plane. Finally, the machining parameters are easily calculated by some known EDM equations to the discharge area. An example is introduced to show that the machining parameters are calculated from the CMM data to a tool electrode.

• Transactions of Materials Processing
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• v.14 no.3 s.75
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• pp.200-206
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• 2005

In general, a lot of small electrode is needed for making precision injection molds, such as cell phone mold and precision connector mold, because of the limitations of NC milling process. Those small electrodes usually have very simple shapes and the actual cutting time is so short, but many NC programs and set-up process, a very complicated and time consuming Job, are needed for each electrode. This paper deals the method for increasing the productivity of machining electrodes. In this work, the process standardization of machining electrode was done and special jig fer machining small electrodes was developed. Automatic tool path optimization software was also developed to minimize tool changing time. In addition, in-line cutting tool measuring system was adopted. The productivity of machining for small electrode has been increased up to $100\%$.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.10
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• pp.187-194
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• 2002

A study on machining electrode for LED (Light Emitted Diode) mold with shaped end-mill is presented. The electrode machining by shaped end-mill has been used for maximizing the productivity in manufacturing semiconductor mold. However, it has not been researched systematically for many difficulties such as the making of shaped end-mill, generation of tool path due to distinctive tool geometry, and so on. Tool path is generated on geometry of the shaped end-mill and cutting force to provide accurate and efficient machining of electrode. The verification program can drive enhancement of productivity, selecting cutting conditions from experiment function of cutting force. Also, compensation of tooling and maching error can make the electrode accurately by modifying tool path. Therefore, the research on machining with shaped end-mill can contribute to enhancement of accuracy and productivity in building semiconductor mold.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1080-1084
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• 2001

In manufacturing a micro die with half spherical cavity by MEDM, it is necessary to prepare an electrode with the same shape. This paper suggests a simple method to manufacture a half spherical electrode based on tool wear. The tool wears more rapidly at the edge of a cylindrical electrode. In order to make a half spherical micro electrode, cylindrical electrode was fed into the workpiece by the distance of its radius. The d/R(depth/Radius) value varied with respect to capacitance and electrode diameter. The smaller the size of electrode was, the closer the electrode tip geometry approached to a half sphere.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.953-956
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• 1997

Micro drilling characteristics by EDM method was investigated. In detail, Micro tool electrode for EDM drilling was machined by use of WEDG method and micro hole was drilled using the machined tool electrode in SUS plate. The machining accuracy and time was compared in a different dielectric fluid. As a result, it was convinced that this method could be utilized as a fabrication technology of micro mold or micro 3 dimensional parts.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.7
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• pp.139-144
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• 2008

Micro electrochemical machining was investigated to machine micro internal features. This method uses a micro disk tool electrode and can easily machine micro features inside of a micro hole, which are very difficult to make by the conventional processes. In order to limit the machining area and localize the electrochemical dissolution, ultra short pulses were used as power source and a micro disk electrode with insulating layer on its surface was used as a tool electrode. By electrochemical process, internal features, such as groove array, were fabricated on the stainless steel plate.