Noncircular Tool Fabrication by WEDG Using Electrode Jump Motion and Noncircular Array Holes Drilling

Electrode jump motion strategy was adopted to fabricate noncircular tool using wire electrical discharge grinding (WEDG). The machining procedure and electrode jump motion strategy for noncircular tool fabrication were determined through experiments. This approach has been verified by successfully machining of rectangular electrode (38μm×38μm, 700μm length) and D-shaped electrode (diameter 45μm, height 42μm, 500μm length). D-shaped array holes of 6×6 matrix were drilled using corresponding single noncircular tool which was manufactured by the adopted machining approach. The array holes have tight diameter tolerance and height tolerance which are both less than 2μm, and positioning errors are both less than 1μm in the direction of the X, Y-axes.