scholarly journals Fabrication of a Large-aspect-ratio Single-thread Helical Electrode using Multiple Wire Electrochemical Micromachining

2020 ◽  
pp. 7796-7808
Author(s):  
Xiaolong Fang ◽  
Keyword(s):  
Aspect Ratio ◽  
Electrochemical Micromachining ◽  
Large Aspect Ratio ◽  
Single Thread ◽  
Wire Electrochemical Micromachining ◽  
Helical Electrode

scholarly journals Wire Electrochemical Micromachining of Aluminum Rings for the Fabrication of Short-Millimeter Corrugated Horns

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 122 ◽  
Author(s):  
Xiaolong Fang ◽  
Xiangyang Wang ◽  
Jiacheng Zhu ◽  
Yongbin Zeng ◽  
Ningsong Qu
Keyword(s):  
Optimal Parameter ◽  
Nitrate Solution ◽  
Groove Depth ◽  
Electrochemical Micromachining ◽  
Experimental Investigations ◽  
Complexing Agent ◽  
Obvious Effect ◽  
Wire Electrochemical Micromachining ◽  
Sodium Nitrate Solution ◽  
Helical Electrode

With the increase of working frequency, the feature size of a corrugated horn will be greatly reduced, causing challenges for fabrication. This paper investigated wire electrochemical micromachining (WECMM) of aluminum rings for assembly of a mandrel for electroforming, which has been a primary method for producing corrugated horns. By utilizing a rotary helical electrode and green additives, the removal efficiency of electrolytic products in WECMM was improved. It was found that the machined slits had good unilateral consistency on the left side of the electrode feeding direction when the electrode rotated clockwise. Complexing agent glutamic diacetic acid (GLDA) can compete with OH− for Al3+ and has an obvious effect in reducing insoluble electrolytic products. From experimental investigations on typical parameters, an optimal parameter combination considering slit homogeneity and machining efficiency was obtained. In an electrolyte solution containing 15 g/L sodium nitrate solution and 15 g/L GLDA, 100 μm-thick aluminum rings with good edge and surface qualities were fabricated at a rate of 1.2 μm/s using a helical electrode with a diameter of 0.3 mm. Finally, these aluminum rings were successfully applied to make an internal corrugated sample with a rib width of 100 μm and a groove depth of 500 μm.

scholarly journals Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

Micromachines ◽  
2020 ◽  
Vol 11 (7) ◽  
pp. 698
Author(s):  
Siying Ling ◽  
Minghao Li ◽  
Yong Liu ◽  
Kan Wang ◽  
Yong Jiang
Keyword(s):  
Surface Roughness ◽  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
304 Stainless Steel ◽  
Electrochemical Micromachining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machined Surface ◽  
Wire Electrochemical Micromachining ◽  
Ultrasonic Assisted

Wire electrochemical micromachining (WECMM) technology is regarded a promising method to fabricate high aspect ratio microstructures on hard-to-machining materials, however, the by-product accumulation in the machining gap limits its application. In this paper, a new method called ultrasonic-assisted wire electrochemical micromachining (UA-WECMM) is proposed to improve the machining performance of WECMM. Firstly, a flow-field simulation in the machining gap was carried out; the results showed that the ultrasonic vibration of electrode can remarkably enhance the mass transport in the machining gap and improve the machining condition. Secondly, experiments were performed to confirm the effect of ultrasonic vibration, which illustrated that the vibration with proper amplitude can reduce the slit width and improve the morphology of machined surface. Moreover, the influence of other machining parameters were also discussed. Finally, a T-type micro connector with good surface roughness (Ra 0.286 μm) was fabricated on a 300-μm-thick 304 stainless steel workpiece and a micro gear (diameter: 3.362 mm; Ra: 0.271 μm) with an aspect ratio of 7 was fabricated on a 2-mm-thick workpiece. It is proved that the proposed ultrasonic-assisted wire electrochemical micromachining method has considerable potential and broad application prospects.

scholarly journals Experimental Study on Ultrasonic Vibration-Assisted WECDM of Glass Microstructures with a High Aspect Ratio

Micromachines ◽  
2021 ◽  
Vol 12 (2) ◽  
pp. 125
Author(s):  
Yan Chen ◽  
Xu Feng ◽  
Gongming Xin
Keyword(s):  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
High Aspect Ratio ◽  
Rapid Development ◽  
Glass Plate ◽  
Slit Width ◽  
Critical Voltage ◽  
Machining Parameters ◽  
Planar Coil ◽  
Helical Electrode

With the rapid development of micro-electro-mechanical systems (MEMSs), the demand for glass microstructure is increasing. For the purpose of achieving high quality and stable machining of glass microstructures with a high aspect ratio, ultrasonic vibration is applied into the micro-wire electrochemical discharge machining (WECDM), which is proposed as ultrasonic vibration-assisted WECDM with a micro helical electrode. Firstly, the formation of a gas film on the surface of the helical electrode in WECDM machining is simulated, meaning the thickness of the gas film can be reduced by adding suitable ultrasonic amplitude, thus reducing the critical voltage, then the machining localization and stability were enhanced. Then, the micro helical electrode with a diameter of 100 μm is used to carry out sets of experiments that study the influence of ultrasonic amplitude, machining voltage, duty factor, pulse frequency, and feed rate on the slit width. The experimental results show that the machining stability and quality are significantly improved by adding suitable ultrasonic amplitude. When the amplitude was 5.25 μm, the average slit width was reduced to 128.63 μm with a decrease of 20.78%. Finally, with the optimized machining parameters, micro planar coil structure and microcantilever structure with a high aspect ratio were fabricated successfully on the glass plate. It is proved that ultrasonic vibration-assisted WECDM with the micro helical electrode method can meet the requirements of high aspect ratio microstructure machining for hard and brittle materials.

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