Micro-Machining & Precision Die-Sinking
Micro-EDM Milling & 3D Micro-Cavity Calculator
Model high-precision micro-EDM milling with cylindrical micro-electrodes. Calculate layer slicing depth ($Z_{\text{step}}$), electrode longitudinal wear compensation ratio ($\vartheta$), discharge energy ($E$), and radial spark gap overcut ($S_g$).
Process & CAM Parameters
Cylindrical micro-rod electrode diameter in microns (µm).
Relaxation generator capacitance in picofarads (pF).
Discharge gap voltage in Volts (V).
Programmed depth per 2.5D raster layer in microns (µm).
Engineering Calculations
Single Pulse Energy
2.12µJ
Radial Spark Overcut (S_g)
3.8µm
Volumetric Wear Ratio (ϑ)
14.5%
Effective Cutting Kerf
157.6µm
Dynamic CAM Toolpath & Vector Preview
Need complete manufacturing prepress guidance and formulas?
Read the Full Micro-EDM Milling Guide →Engineering Principles & Formulations
Micro-EDM Milling employs rotating cylindrical micro-electrodes (tungsten, copper-tungsten) dressed on-machine via Wire Electro-Discharge Grinding (WEDG) to mill complex 3D micro-cavities layer by layer.
Key mathematical relationships include:
- Discharge Pulse Energy: $$E = \frac{1}{2} C U_0^2$$ (Nanosecond RC circuits achieve sub-microjoule pulses for mirror surface finishes $Ra < 0.05\,\mu\text{m}$).
- Spark Gap Overcut: $$S_g = c_1 \cdot E^{0.33}$$ (Must be offset outward on all internal CAM boundary contours).
- Uniform Wear Method (UWM): Longitudinal electrode wear compensation ($\Delta Z$) is applied dynamically along the toolpath: $$\Delta Z = \vartheta \cdot \frac{A_{\text{cavity}} \cdot Z_{\text{step}}}{A_{\text{electrode}}}$$