Towards the effective tool wear control in micro-EDM milling

Giuliano Bissacco, J. Valentincic, Hans Nørgaard Hansen, B. D. Wiwe

Research output: Contribution to journalJournal articleResearchpeer-review


The electrode wear in micro-electrical discharge milling (micro-EDM milling) is one of the main problems to be solved in order to improve machining accuracy. This paper presents an investigation on wear and material removal in micro-EDM milling for selected process parameter combinations typical of rough and finish machining of micro-features in steel. The experiments were performed on state-of-the-art micro-EDM equipment. Based on discharge counting and volume measurements, electrode wear per discharge and material removal per discharge were measured for several energy levels. The influence of the accuracy of volume measurements on the electrode wear per discharge and on the material removal per discharge are discussed, and the issues limiting the applicability of real time wear sensing in micro-EDM milling are presented.
Original languageEnglish
JournalInternational Journal of Advanced Manufacturing Technology
Issue number1-4
Pages (from-to)3-9
Publication statusPublished - 2010


  • Pulse detection
  • Micro-electrical discharge machining
  • Tool wear

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