Experimental Study on Modifying Square Electrodes for Precise Square-hole Electric Discharge Machining
To address issues with machining difficulty,poor accuracy,surface quality,and low yield rates associated with narrow and long copper electrodes used in EDM square hole finishing,we propose an electrode correction method and conduct square electrode correction experiments.Electrodes that did not meet the dimensional accuracy requirement of 0.02 mm and straightness requirement of 0.05 mm underwent correction experiments.The electrodes were straightened to 0.02 mm and then fine-ground using a grinding jig.This resulted in a straightness of less than 0.01 mm and a surface roughness of less than Ra1.6 μm.The machining accuracy and surface quality of the square electrodes were improved through the electrode correction and fine-grinding method.This improvement enables the square electrode to meet precision requirements,resulting in an increase in the electrode's qualified rate to over 60%.The EDM test was conducted to create square holes using qualified electrodes,resulting in significant improvements in both corner accuracy and surface quality.The square hole has a minimum corner radius of 0.04 mm,a machining taper of 0.03 mm,and a surface roughness of Ra2.219 μm.
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