Investigation on electrode wear in micro-edm drilling

Micro-EDM drilling is extensively utilized in various industrial sectors due to its capability to machine all types of conductive materials, irrespective of their mechanical properties. This technology is particularly advantageous for drilling applications requiring high aspect ratios and precision. However, electrode wear, both frontal and radial, poses significant challenges, especially in blind hole drilling. This study proposes a mechanical method to measure electrode geometry through touch operations on a sharp target, varying the spindle rotation angle and Z depth. The method's effectiveness was validated through extensive experiments on Ti6Al4V plates using cylindrical and tubular electrodes of different diameters. The study varied energy types and tested new and steady-state electrodes. Results demonstrated the method's ability to detect changes in electrode tip shape under different conditions, revealing phenomena such as the correlation between electrode runout and wear, and the impact of internal washing on tip shape.