scholarly journals Fast Fabrication of Complex Surficial Micro-Features Using Sequential Lithography and Jet Electrochemical Machining

Micromachines ◽  
2020 ◽  
Vol 11 (10) ◽  
pp. 948
Author(s):  
Ming Wu ◽  
Krishna Kumar Saxena ◽  
Zhongning Guo ◽  
Jun Qian ◽  
Dominiek Reynaerts
Keyword(s):  
Contact Process ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Shape Error ◽  
Shape Deviation ◽  
Shape Accuracy ◽  
High Productivity ◽  
Micro Features ◽  
Surface Microstructures ◽  
Jet Electrochemical Machining

This paper presents fabrication of complex surficial micro-features employing a cross-innovative hybrid process inspired from lithography and Jet-ECM. The process is referred here as mask electrolyte jet machining (MEJM). MEJM is a non-contact machining process which combines high resolution of lithography and greater flexibility of Jet-ECM. It is a non-contact process which can fabricate variety of microstructures on difficult-to-machine materials without need of expensive tooling. The presented work demonstrates the process performance of this technology by statistical analysis and multivariate kernel density estimation (KDE) based on probabilistic density function. Micro-letters are fabricated as an example of complex surficial structure comprising of multiple intersecting, straight and curved grooves. The processing response is characterized in terms of geometrical size, similarity ratio, and cumulative shape deviation. Experimental results demonstrated that micro letters with good repeatability (minimum SD of shape error ratio 0.297%) and shape accuracy (minimum shape error of 0.039%) can be fabricated with this technology. The results suggest MEJM could be a promising technology for batch manufacturing of surface microstructures with high productivity.

scholarly journals The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 404 ◽  
Author(s):  
Xinmin Zhang ◽  
Xudong Song ◽  
Pingmei Ming ◽  
Xinchao Li ◽  
Yongbin Zeng ◽  
...  
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Horizontal Orientation ◽  
Jet Electrochemical Machining ◽  
Machining Characteristics ◽  
Machining Localization ◽  
Vertical Jet

Jet electrochemical machining (Jet-ECM) is a significant prospective electrochemical machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet machining, and the effect of jet orientations on machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of machining localization and a reduction of MMR for horizontal jet electrochemical machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve machining accuracy.

Study of Electrochemical Jet Machining Process

1996 ◽  
Vol 118 (4) ◽  
pp. 490-498 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
R. Balkrishna
Keyword(s):  
Turbine Blades ◽  
Electrochemical Machining ◽  
Small Diameter ◽  
Machining Process ◽  
Workpiece Material ◽  
Precise Control ◽  
Machining Rate ◽  
Jet Electrochemical Machining ◽  
The Relationship ◽  
Electrolyte Jet

Jet Electrochemical Machining (ECJM) employs a jet of electrolyte for anodic dissolution of workpiece material. ECJM is extensively used for drilling small cooling holes in aircraft turbine blades and for producing maskless patterns for microelectronics parts. ECJM process drills small diameter holes and complex shape holes without the use of a profile electrode. One of the most significant problems facing ECJM user industries is the precise control of the process. A theoretical analysis of the process and a corresponding model are required for the development of an appropriate control system. This paper presents a mathematical model for determining the relationship between the machining rate and working conditions (electrolyte jet flow velocity, jet length, electrolyte properties, and voltage) of ECJM. This model describes a distribution of electric field and the effect of change of conductivity of electrolyte (caused by heating) on the process performance. A maximum dissolution rate is determined from the allowable increase of electrolyte temperature. Experimental verification of theoretical results is also presented.

scholarly journals Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

2021 ◽  
Author(s):  
Dina Becker ◽  
Steffen Boley ◽  
Rocco Eisseler ◽  
Thomas Stehle ◽  
Hans-Christian Möhring ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Closed Loop ◽  
Deposition Process ◽  
Metal Wire ◽  
Machining Process ◽  
Machining Processes ◽  
Initial State ◽  
Additive Process ◽  
Shape Accuracy ◽  
Loop Control

AbstractThis paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

scholarly journals MODELLING OF THE OF ELECTROCHEMICAL MACHINING PROCESS

2007 ◽  
Vol 40 (18) ◽  
pp. 475-480
Author(s):  
Laurentiu SLATINEANU ◽  
Oana DODUN ◽  
Loredana SANTO ◽  
Margareta COTEATA ◽  
Adriana MUNTEANU
Keyword(s):  
Electrochemical Machining ◽  
Machining Process

Method of Assessment of Casting Accuracy and Minimization of Machining Allowances

2012 ◽  
Author(s):  
Andrzej Gessner ◽  
Roman Staniek
Keyword(s):  
Machine Tool ◽  
Accuracy Assessment ◽  
Assessment Method ◽  
Machining Process ◽  
Shape Accuracy ◽  
Construction Design ◽  
Optical Scanner ◽  
Course Of Action ◽  
Reference Design ◽  
Method Of Assessment

The publication demonstrates an accuracy assessment method for machine tool body casting utilizing an optical scanner and a reference design of the machine tool body. The process allows assessing the casting shape accuracy, as well as determining whether the size of the allowances of all work surfaces is sufficient for appropriate machining, corresponding to the construction design. The described method allows dispensing with the arduous manual operation - marking out. Marking out, depending on the size and complexity, might take several working shifts for prototype casting. In case of large and elaborate casts, as those of machine tool bodies, marking out is often restricted only to the first cast of the desired body produced in a given casting mold. Such course of action is based on an assumption that casting is reproducible; hence, no need to assess each and every individual cast. While this approach saves time, it often results in late detection of casting errors (allowance shifts or insufficiencies) during the actual machining process. That, in turn, results in considerable losses due to the disruption of the work process and often demands cast repair. The aim of the hereby presented study is to introduce a new technological premise dispensing with manual marking out as well as allowing fast verification of the cast shapes.

Sign in / Sign up

Export Citation Format

Share Document