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Surface Studies For Electrodischarge Machining (EDM) With Electropolishing and Comparisons With Single-Point Diamond Machining - Part 1
Surface Studies For Electrodischarge Machining (EDM) With Electropolishing and Comparisons With Single-Point Diamond Machining - Part 1
I. Vendor information
1. Job shop= Ron Witherspoon, Inc. (RWI)., 430 Industrial St., Campbell, CA.
Process= wire EDM with 4 mil brass wire coated with zinc.
II. Summary
The machining accuracy RWI held over a cutting length of 0.262" is about 1.5 m.
For a longer cutting length of 0.744", the accuracy is about 9 m. The smallest corner
radius RWI can machine is about 0.003", which is adequate for our project. It is apparent
that RWI can not give us the kind of machining accuracy required for making 90 GHz
structures.
time ), also pits on the polished surface. Longer processing time( over 8 minutes ) does
not prove to be beneficial to us. The surface smoothness does not get improved, especially
near the step edge where the current density is higher. Some waviness on the metal surface
has developed due to excessive electropolishing treatments. The metal removal rate does
2
not increase in proportion to the processing time of EP. Further tests with different
settings of electropolishing are needed in order to reduce the number of pits and eliminate
the surface waviness. The effects of pits under high RF power has yet to be understood.
All workpieces are immersed in a 30-gallon tank with little agitation in the polishing
solution. The parameters used for all workpieces are given in SPEC. No. EP4( refer to
A. Farvid for details ). The voltage setting is 8 volts for all workpieces.
Appendix:
~.5
~.5
~2 R .002
End View
.744
.744
NOTES:
ATTENTION : The EDM parameters used for this module have to be documented for
the latter surface studies with electropolishing process.
Unless otherwise specified: Stanford Linear Accelerator Center SK- PJ- TEST001
all dimensions in inches. Tolerances: Engineering Sketch ARDB
.X .02, .XX .01, .XXX .005 Engr: P.J. Chou Approvals HIGH GRADIENT STRUCTURE
.XXXX .0001 EDM + ELECTROPOLISHING TEST
Surfs finishes 32 max
5- 8- 96'
1
One damaged piece of Damped detuned Structure(DDS) for the NLCTA has been
both DDS component and the EDM'ed workpiece. The following results are for
workpiece "TEST001-C".
scanner(using red laser), provided by UBM, Co. in Sunnyvale. The height accuracy of
the scanner is 0.1 m. The picture depicts the surface finish of EDM'ed copper.
2
scan002.tiff= 3-D surface profile scan provided by UBM. The picture depicts the
scan006.tiff= The cut edge of damping slot of the DDS component machined by
scan008.tiff= A close-up look at scan007.tiff. The small bump indicates the existence
of zinc.
scan010.tiff= SEM micrograph of EDM'ed copper surface. Note that two scraping
lines caused by the stylus of profilometer. Copper is too soft to be scanned by doing
contact measurements.
scan012.tiff= SEM micrograph of the cut edge of DDS damping slot. The burrs
scan013.tiff= Photograph of EDM'ed copper surface with EP. The small shining dots
are craters caused by oxygen bubbles created during EP. The large crater near the
upper right corner of the picture is caused by the wire. The projection light was turned
close-up picture of scan017.tiff. Comparing with scan008.tiff, the bump indicating the
debris are probably dust particles. Those pin holes were caused by oxygen bubbles
scan022.tiff= A close-up picture of the pin hole on the EDM'ed copper surface after
EP.
1
Workpiece= TEST001-C.
only piece shows zinc from the EDM wire and fairly high carbon level. The EP piece,
however, has no zinc left and a low carbon level. The surface topography was
roughness although there is still evidence of the EDM wire groves in the EP'ed surface.
Also apparent were shallow depressions in the EP'ed sample, of various diameters.
There are probably from surface bubbles formed during the EP process which were
(m) 2.
2
(m)2.
13122401.eps).
3
13122410.eps)
4
(m)2.
(m) 2.
5
1
Workpiece TEST001-B was treated with EP for 4 minutes, the same processing time
as TEST001-C. The only difference is that TEST001-B was not cut in half before EP.
After EP treatments, workpiece TEST001-B was cut away and examined by SEM.
edge
central area
Side View Top View
2
along the crystal grain boundary of copper were observed which may be caused by the
times.
4
side edge
Scan023.pict= SEM micrograph of the step edge area( 8 minutes EP ). Notice the
holes.
7
times.