Novel tool design method for orbiting electrical discharge machining

Orbiting EDM has the advantages of superior machining quality over static EDM due to advanced flushing. However, improper tool correction to the relative motion in orbiting EDM will result in dimension errors of the product. As features vary in morphology, tool design for orbiting EDM is a challenging task, particularly for mould comprises assorted features. A strategy for correcting the orbital motion to the tool shape is proposed in this study. Effect of different orbital types to the feature's shapes is discussed from its geometrical point of view. This method also applies for orbiting automation by utilizing feature recognition to identify features inside a CAD model and recommends the corresponding orbiting pattern for all detected features. The shaped tool created with this method is capable of fabricating a complex mould precisely. More than 20 different features with different orientations to the machining axis have been tested to accommodate real designs in mould industries.