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DESIGN AND FABRICATE LIGHTWEIGHT AND

PORTABLE MICRO-EDM TABLE
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Mechanical System Design, 25 Mar 2016

Universiti Malaysia Pekan, Pahang, Malaysia

DESIGN AND FABRICATE LIGHTWEIGHT AND PORTABLE MICRO-EDM

TABLE.
W.T. TAN
Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26600 Pekan,
Pahang, Malaysia,
*
Email: [email protected]

ABSTRACT
The micro-electrical discharge machining (micro-EDM) process has been proved to
be appropriate for making 3D micro parts that are difficult and even impossible to
manufacture by other processes. The purpose of this project is to design a lightweight and
portable micro-EDM table. We decide to design the working table like a trolley which is
consist a rack and a liftable working area which is able to adjust the height of the table.
The reason is because it is easier to move compare to ordinary table and it is able to be
static when the EDM machine is operating because at the wheel has install a breaking
system which is able to fix the wheel from movement. The main material that we use in
our project is mild steel and plywood. The materials that we chose has some physical
properties like steel has high strength and high stiffness while plywood has lightwood and
both this materials are affordable which is within our budget (RM500). Proper selection
of the machining parameters can result in better machining performance in the microelectrical discharge machining (EDM) table. This study emphasizes the technical skill
that we learn in manufacturing process laboratory like machining (sheet metal fabrication
and welding) and analytical skill such as force analysis and finite element analysis (FEA).
Keywords: Micro-EDM, Table.

INTRODUCTION
Electrical discharge machining (EDM) and can be knowns as spark machining is an
manufacturing process to make or to obtain an desired shape by using electrical
discharges to remove some of the parts of the materials. [1-3] The machine that we use
to undergo this process is called electrical discharge machining machine (EDM machine)
In this project, we have been requested to fabricate a micro-EDM machine table which is
light-weighted and portable, most important is this table need to withstand the weight of
the micro-EDM machine which is approximately 20kg. Micro electro-discharge
machining (EDM) has been adopted as one of most valuable techniques for
micromachining because of its excellence in the fabrication of precise micro hole,
micromechanical parts, and complex microstructures. However, the occurrence of
electrode wear is unavoidable and very critical since tool shape degeneration directly
affects the depth and shape of a microstructure. [4-7] When a micro cylindrical electrode
is used for EDM drilling or milling, the shape of the tool electrode rapidly changes during
machining. [8-12] Tool wears occur both at the end and on the side of the tool electrode
and are expressed as front wear and corner wear, respectively. [13-17] Front wear causes
errors in the electrode length and thus contributes to insufficient depth of a microhole in

micro-EDM, particularly for drilling. [18-24] Corner wear leads to rounded edges of the
tool electrode and thereby resulting in geometrical inaccuracy of a microstructure in EDM
milling. [25] In order to solve the tool wear problem as well as improve the machining
accuracy in EDM, many approaches including tool wear prediction, sensing, modeling,
and compensation have been presented. In 1770, the first erosive effect of electrical
discharges was invented by English physicist Joseph Priestley. [26] After 200 years, two
Russian scientists, B.R. Lazarenko and N.L Lazarenko has been assigned to investigate
and do research about the prevention of the erosion of tungsten electrical contacts due to
sparking. They accidentally found that when the electrode were immersed in a dielectric
fluid the erosion was more accurate and precise to be controlled. [27-29] At the same
time, one of the American team, Harold Stark, Victor Hardin and Jack Beaver has
developed and EDM machine which can remove broken drills and taps from aluminium
castings. [30] At first, they used feeble electic-etching tools to construct their machine
but this idea was failed. After that found that the combination of the automatic spark
repetition and fluid replacement with an electromagnetic interrupter will generate much
more powerful spark. [31-32] All of this method we called it as Die-sink EDM Generally
EDM machine is used for hard metal machining or those metal which is hard to be
machined by traditional techniques. [33-35]
CONCLUSIONS
This project has provided a well platform for our team members to more understand what
is micro-EDM machine. Besides, throughout this project, we have learnt a lot of
machining knowledge and skills for example how to drill. Lastly we have learnt how to
cooperate with each other.

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