A novel method for fabrication of die and mold in orbiting electrical discharge machining - Proposition of electrode design

Orbiting EDM offers a better machining quality toward static EDM. However, due to the relative motion between the tool electrode and the workpiece, the dimensional cavities will deviate from the design requirement. This research aims to develop a simulation method to fabricate tool electrodes which able to solves the raised problem by using Z-map model. The algorithm was adopted from EDM toolmaking process. Simulation result reveals that machining accuracy in orbiting EDM is dependent on the required features, type of orbit path used and orbit gap value. Examples are shown to demonstrate the effectiveness of the proposed method.