Micro-machining and micro-grinding with tools fabricated by micro electro-discharge machining

This paper provides an overview of several approaches to micro-machining by mechanical and electro-discharge means of material removal. Two steps are required in machining micro features. Firstly, a custom-shaped tool is created from suitable stock. In many cases, this is carried out using a small-scale version of wire Electro-Discharge Machining (EDM) in tool materials such as sintered PolyCrystalline Diamond (PCD) or tungsten carbide. Then the micro-tool can be used as a miniature end mill, drill or abrasive wheel. Each of these mechanical machining methods can be combined with EDM to achieve a customisable surface finish and feature accuracy. Trade-offs such as tool wear, Material Removal Rate (MRR) and machining time are discussed in this paper within the context of several examples.