3D Micro-EDM Using CAD/CAM

It is necessary to integrate CAD/CAM systems with micro-EDM to generate tool paths when simple shaped tools are used to machine three-dimensional (3D) micro parts. Currently available CAD/CAM systems cannot be directly used because of the continuous tool electrode wear during machining. This paper proposes an approach to integrate CAD/CAM systems with micro-EDM while accounting for tool wear using a recently developed uniform wear method. This approach is verified by successfully generating very complex 3D micro cavities. Additionally, the feasibility of the approach is illustrated by generating complex macro cavities using conventional EDM with single simple shaped electrodes.