Abstract: Micro electro discharge milling (ED-milling) with simple electrode is found wide application in micro 3D structure machining due to the characters of adaptation and handleability. However, there will be some vestige remains on the machined surface during ED-milling no matter how to reduce the discharge power, especially in the complicated surface can not be expressed with normal equations. To solve the problems of vestige remains, the lamination’s strategies of micro ED-milling, the way of the track’s generation and the arithmetic of smoothness are studied systemically. At the same time, with the way of isoparametric interpolation, the machined curved sur-faces of lamination are well corrected. By using the technology of ED-milling CAD/CAM developed by authors, some sub-millimeter level micro 3D complicated parts including spherical surface, cylinder and NURBS surface are machined.

Key words: CAD/CAM, ED-Milling, Micro, Smoothness