HANNOVER MESSE 2019, 01 - 05 April
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Measurable microcavities

Process-overlapping control of micro track errosion.

Logo Karlsruher Institut für Technologie


Karlsruher Institut für Technologie

Exhibitor details
Exhibitor details
Logo Measurable microcavities

Product description

For series production of microcomponents by replication processes, precise molds made of wear-resistant materials are required. Micro track erosion is a  flexible method to represent such cavities. The cylindrical tool electrode is subject to wear during track erosion as well as during all spark erosion processes. As the wear behavior changes with increasing depth of the cavity, frequent deviations from the desired depth of the cavities or irregularities of the surface result when producing a cavity. Conventional wear compensation via a constant feed motion of the electrode is not sufficiently accurate and requires extensive experience and know-how.At the wbk Institute of Production Science, a process-overlapping and automatic erosion control process has been developed. The sensors required are integrated in the micro erosion machine to machine and measure a component in a fixing unit. In this way, machine kinematics and control can be used for the measurement process. The deviation of the depth from the desired value after the first machining process is measured by a confocal white-light sensor. To measure every machined point of the workpiece and to determine the maximum and minimum values of the erosion depth, wear control is based on the tracks of the machining file. Upon an evaluation of the measured data based on a previously defined truncation criterion, it is decided whether a sufficient component quality is reached or a second machining program has to be generated and executed automatically. During the test production of a cavity with process-overlapping erosion control, a depth of 98.2 µm of the desired 100 µm was reached after five machining steps. The undulation of the surface generated was in the range of the achievable surface roughness. Specific setting of the component quality can be ensured by this automatic erosion control.

Product website

Hall 2, Stand B16

(Main stand)

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