Abstract

Machining miniature cylindrical parts are of great challenge because the pressure that tools or grinding wheels exert on parts such as the micro parts/electrodes can cause the parts to deflect, making it difficult to achieve the desired accuracy. In fact, in some cases it’s impossible to machine such tiny parts using these conventional methods. Unlike traditional cutting and grinding processes, which rely on the force generated by a harder tool or abrasive materials to remove the softer work piece material, the electrical discharge machining [EDM] process utilizes electrical sparks or thermal energy to erode the unwanted material and generate the desired shape. One further improvement is to rotate parts in a spindle mounted on the table of a wire EDM unit and allow the wire to “grind” the parts to shape and size. This is advantageous for micro-machining applications where material is removed electrically via spark erosion, not mechanically. The chance for deflection is eliminated because