Papers by Author: Guo Zheng Zhu

Abstract: The inkjet template is an important part of digital printing equipment. The diameter of hole arrays on the template determines the consistency of the ink droplet and thus affects print quality. To improve the printing performance of digital printing equipment, this study investigated the effect of micro-electrical discharge machining (micro-EDM) on the diameter consistency of micro-hole arrays on an inkjet template. Combining block electrical discharge grinding and wire electrical discharge grinding enabled the online processing of the fine tool electrode, whose diameter can be stably controlled at less than 45 μm, whose maximum diameter deviation was about 1 μm. The tool electrode can also be used to process micro-hole arrays. Subsequently, the relationship between the discharge energy of micro-EDM and the erosion material was theoretically analyzed, as was the effects of the diameter consistency of the micro-electrode itself on that of the micro-hole array processed by the micro-electrode and the relationship between processing parameters and the discharge gap between the micro-electrode and the workpiece. Experimentations were conducted on the effect of the flow rate, flush angle, and rotation speed of the electrode and the resistivity of de-ionized water to the diameter consistency of the micro-hole arrays. On the optimized parameters, a 16×16 micro-hole array with a diameter deviation of less than 2 μm was successfully processed, and the average diameter of the holes, about 44 μm, was used for the inkjet template. Beside, an electrode with a diameter of 14μm is also machined and it was used to process a 8×8 micro-hole array, whose diameter deviation is 0.9μm and average diameter is less than 20μm. Large number of experiments show that by the proposed method, one electrode can stably machined 800 holes with diameter less than 50μm, and their diameter deviation is less than 3μm. ​The digital printing equipment with these holes can meet the current demand for components with micro-hole arrays.

Abstract: As demands for the micro array holes in modern industry and the characteristics of micro Electrical Discharge Machining (micro EDM), a new type micro EDM machine tool used to machine micro array holes was designed and manufactured. The machine tool contains following systems: the mechanism system, the control system, the pulse generator system and other auxiliary systems. Each system was studied respectively. Base on a large number of experiments, finally, a sample with 256 array holes was processed by the machine tool. The diameter of single hole is 45µm and precision of the holes is ±1µm. The sample has been successfully applied to R & D test of micro nozzle components

Abstract: Experiments of micro-EDM in gas (dry MEDM) were conducted on the conditions of an external supplying gas mode based on a RC pulse generator. The objective of the work is to optimize machining parameters of the dry MEDM and investigate the machining performance of the ultrasonic induced workpiece vibration. Micro solid copper electrodes were fabricated on line by the block grinding method. Range analysis results of the Taguchi approach indicate that capacitance, servo feed speed have great effect on the material remove rate (MRR); and capacitance and open voltage are main influencing factors on the tool relative wear ratio (TWR). An optimal parameters combination was obtained under the experimental conditions. The experimental results of the ultrasonic induced workpiece vibration demonstrate that high frequency workpiece vibration with a suitable input current could improve MRR and TWR of the dry MEDM.

Abstract: Micro-EDM technology has the advantages of no-contact and no-cutting force, it has been used in many fields. In order to use micro-EDM to machine proprietary micro array holes, which needs high precise of hole spacing and consistent hole diameter, a new macro-micro dual-drive system of micro-EDM have been made. It uses macro drive to move to a place, measures the error with the high precise grating, and uses micro drive to compensate the error. Online measurement proved that this method has important value if it will be used in micro-EDM.