Electrical discharge machining (EDM) with its advantages of small working force

good controllability

etc.

has become more and more widely used in the field of micro and small hole manufacturing

however

for high-aspect-ratio micro and small hole machining

there are still some technical difficulties such as slow cooling

poor debris flushing

high tool wear and difficult to monitor and control

etc. With analyzing the mechanics and characteristics of EDM

a machine for rapidly EDM micro and small holes is designed and developed. The machine is vertically laid out

applying a rotary-vibrate mechanism with tool rotating and workpiece vibrating for the purpose of rapid cooling and debris flushing in the working process; it adopts industrial PC (IPC) with PCI card and PMAC card plugged to make data acquisition and motion control work well together. In order to solve the problem that discharge states are difficult to detect due to severely distorting sparking signals and unstable sparking states in EDM

a successive mapping detection method of discharge states based on two-stage fuzzy logic is proposed and a double-closed-loop control system is designed as well to achieve rapid response and precise control of the working process. Experiments show that this machine is suitable for rapidly manufacturing high-aspect-ratio micro and small holes and is of stable performance and high reliability.