scholarly journals Experimental Research on Machining Localization and Surface Quality in Micro Electrochemical Milling of Nickel-Based Superalloy

Micromachines ◽  
2018 ◽  
Vol 9 (8) ◽  
pp. 402 ◽  
Author(s):  
Yong Liu ◽  
Yong Jiang ◽  
Chunsheng Guo ◽  
Shihui Deng ◽  
Huanghai Kong
Keyword(s):  
Surface Quality ◽  
Electrochemical Machining ◽  
Nanosecond Pulse ◽  
Machining Parameters ◽  
Pulse Technique ◽  
Nickel Based Superalloy ◽  
Good Surface ◽  
Pulse On Time ◽  
Electrochemical Milling ◽  
Machining Localization

Micro electrochemical machining is becoming increasingly important in the microfabrication of metal parts. In this paper, the machining characteristics of micro electrochemical milling with nanosecond pulse were studied. Firstly, a mathematical model for the localization control of micro electrochemical milling with nanosecond pulse was established. Secondly, groups of experiments were conducted on nickel-based superalloy and the effects of parameters such as applied voltage, pulse on time, pulse period, electrolyte concentration and electrode diameter on machining localization and surface roughness were analyzed. Finally, by using the optimized machining parameters, some 2D complex shapes and 3D square cavity structures with good shape precision and good surface quality were successfully obtained. It was proved that the micro electrochemical milling with nanosecond pulse technique is an effective machining method to fabricate metal microstructures.

scholarly journals Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

Coatings ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 406
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
Tomas Prokes ◽  
...  
Keyword(s):  
Surface Quality ◽  
Regression Equations ◽  
Graphite Electrodes ◽  
Copper Electrodes ◽  
Good Surface ◽  
Transmission Electron ◽  
Hardness Change ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machined Surfaces

Die-sinking electric discharge machining (EDM) is an indispensable technological operation, especially in the production of molds and all internal and external shapes and cavities. For this reason, the effect of machine parameter settings (open-voltage, pulse current, pulse on time, and pulse off time) on the machining of two types of steels, 1.2363 and 1.2343ESR, was carefully investigated using graphite or copper electrodes in 10 mm × 10 mm or 100 mm × 100 mm shapes. For this purpose, a two-level half factor experiment was performed with one replication at the corner points and two replications at the central points, with a total of 80 rounds. The subject of the evaluation was the topography and morphology of machined surfaces including a detailed analysis of surface and subsurface defects in the form of cracks including the creation of regression equations describing the probability of crack occurrence. Furthermore, a study of the local hardness change in the subsurface area was performed, and lamellas were also made and studied by transmission electron microscopy. It has been found that by using die-sinking EDM, it is possible to effectively predict the probability of cracking on machined surfaces and also on machine 1.2363 and 1.2343ESR steels with a very good surface quality of Ra 1.9 and 2.1 µm using graphite electrodes. These findings will ensure the production of parts with the required surface quality without cracks, which is a crucial aspect for maintaining the required functionality and service life of the parts.

Fabrication of Micro Structures by Ultra Short Voltage Pulse Electrochemical Machining

2009 ◽  
Vol 419-420 ◽  
pp. 813-816 ◽  
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Wan Sheng Zhao
Keyword(s):  
Voltage Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Stray Current ◽  
Micro Fabrication ◽  
Micro Hole ◽  
Micro Structures ◽  
Machining Localization

. The purpose of this paper is to study the application of electrochemical machining (ECM) technology for the fabrication of micro structures. The stray current corrosion, i.e. machining localization is a critical obstacle to micro fabrication for ECM. To machine micro structures by electrochemical machining ultra short voltage pulse is used. The effects of electrochemical machining parameters such as voltage, pulse duration, pulse frequency, and electrolyte composition on the machining accuracy were studied. In experiments, a micro hole was machined on stainless steel with cylindrical and square electrodes to investigate these effects.

scholarly journals Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

Sensors ◽  
2020 ◽  
Vol 20 (22) ◽  
pp. 6617
Author(s):  
Yong Liu ◽  
Haoran Chen ◽  
Shenghai Wang ◽  
Kan Wang ◽  
Minghao Li ◽  
...  
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Rapid Development ◽  
Three Dimensional ◽  
Machining Performance ◽  
Good Surface ◽  
Anode Dissolution ◽  
Compound Method ◽  
Metal Microstructure ◽  
Electrochemical Milling

With the rapid development of MEMS, the demand for metal microstructure is increasing. Micro electrochemical milling technology (MECM) is capable of manufacturing micro metallic devices or components based on the principle of electrochemical anode dissolution. To improve the capacity of MECM, this paper presents a compound method named ultrasonic vibration-assisted micro electrochemical milling technology (UA-MECM). Firstly, the simulation and mathematical model of UA-MECM process is established to explain the mechanism of ultrasonic vibration on micro electrochemical milling. Then, the effects of ultrasonic parameters, electrical parameters and feedrate on machining localization and surface quality are discussed considering sets of experiments. The surface roughness was effectively reduced from Ra 0.83 to Ra 0.26 µm with the addition of ultrasonic vibration. It turns out that ultrasonic vibration can obviously improve machining precision, efficiency and quality. Finally, two- and three-dimensional microstructures with good surface quality were successful fabricated. It shows that ultrasonic vibration-assisted electrochemical milling technology has excellent machining performance, which has potential and broad industrial application prospects.

scholarly journals Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

Chemosensors ◽  
2020 ◽  
Vol 8 (3) ◽  
pp. 62
Author(s):  
Huanghai Kong ◽  
Yong Liu ◽  
Xiangming Zhu ◽  
Tengfei Peng
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
High Speed ◽  
Electrochemical Machining ◽  
Machining Parameters ◽  
Mechanical Grinding ◽  
High Quality ◽  
Passive Behavior ◽  
Ultrasonic Assisted ◽  
Small Holes

Electrochemical grinding (ECG) technique composed of electrochemical machining (ECM) and mechanical grinding is a proper method for machining of difficult-to-cut alloys. This paper presents a new ultrasonic assisted electrochemical drill-grinding (UAECDG) technique which combines electrochemical drilling, mechanical grinding, and ultrasonic vibration to fabricating high-quality small holes on superalloy. By applying ultrasonic vibration to high-speed rotating electrode in ECG, machining stability, efficiency, and surface quality can be obviously improved. Firstly, the electrochemical passive behavior of superalloy is studied, the mathematical model and simulation of gap electric field are established. Then, several experiments are conducted to investigate the influence of applied voltage, feed rate and ultrasonic amplitude on the machining quality. The balance of material removal between electrochemical reaction and mechanical grinding is achieved by optimizing the machining parameters. It reveals that the surface quality as well as machining stability and efficiency can be significantly improved by applying rotating ultrasonic vibration to the ECG process. Finally, several small holes of high quality have been machined successfully along with surface roughness of hole sidewall decreases from Ra 0.99 μm to Ra 0.14 μm by UAECDG.

Experimental Investigation on Micro Electrochemical Milling of Nickel-Based Superalloy

2012 ◽  
Vol 229-231 ◽  
pp. 2436-2439
Author(s):  
Yong Liu ◽  
Yong bin Zeng
Keyword(s):  
Electrolyte Concentration ◽  
Experimental System ◽  
Electrochemical Process ◽  
Machining Accuracy ◽  
Nickel Based Superalloy ◽  
Optimization Parameters ◽  
Micro Structures ◽  
2D And 3D ◽  
Pulse On Time ◽  
Electrochemical Milling

In this paper, sets of experiments are carried out on the difficult-to-machine nickel-based superalloy based on the principle of micro electrochemical milling with nanosecond pulse current. First, an experimental system for meeting the requirements of the EMM process is established. Second, sets of experiments are carried out to investigate the influence of some of the predominant electrochemical process parameters, such as machining voltage, pulse on time, and electrolyte concentration, on machining accuracy. Finally, using the optimization parameters, a series of 2D and 3D micro structures have been successfully obtained.

scholarly journals Multi-Physics Coupling Modeling and Experimental Investigation of Vibration-Assisted Blisk Channel ECM

Micromachines ◽  
2021 ◽  
Vol 13 (1) ◽  
pp. 50
Author(s):  
Juchen Zhang ◽  
Shasha Song ◽  
Junsheng Zhang ◽  
Weijie Chang ◽  
Haidong Yang ◽  
...  
Keyword(s):  
Flow Field ◽  
Surface Quality ◽  
Complex Structure ◽  
Electrochemical Machining ◽  
Coupling Model ◽  
Two Phase ◽  
Field Coupling ◽  
Good Surface ◽  
Material Hardness ◽  
Relative Errors

Due to its advantages of good surface quality and not being affected by material hardness, electrochemical machining (ECM) is suitable for the machining of blisk, which is known for its hard-to-machine materials and complex shapes. However, because of the unstable processing and low machining quality, conventional linear feeding blisk ECM has difficulty in obtaining a complex structure. To settle this problem, the vibration-assisted ECM method is introduced to machine blisk channels in this paper. To analyze the influence of vibration on the process of ECM, a two-phase flow field model is established based on the RANS k-ε turbulence model, which is suitable for narrow flow field and high flow velocity. The model is coupled with the electric field, the flow field, and the temperature field to form a multi-physics field coupling model. In addition, dynamic simulation is carried out on account of the multi-physics field coupling model and comparative experiments are conducted using the self-developed ECM machine tool. While a shortcut appeared in the contrast experiment, machining with vibration-assisted channel ECM achieved fine machining stability and surface quality. The workpiece obtained by vibration-assisted channel ECM has three narrow and straight channels, with a width of less than 3 mm, an aspect ratio of more than 8, and an average surface roughness Ra in the hub of 0.327 μm. Compared with experimental data, the maximum relative errors of simulation are only 1.05% in channel width and 8.11% in machining current, which indicates that the multi-physics field coupling model is close to machining reality.

scholarly journals Performance Improvement of High-speed Edm and Ecm Combined Process by Using a Helical Tube Electrode With Matched Internal and External Flushing

2021 ◽  
Author(s):  
Lei Ji ◽  
Yan Zhang ◽  
Guoqian Wang ◽  
Jie Zhang ◽  
Wentao Yang
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Machining Parameters ◽  
Tube Electrode ◽  
Helical Tube ◽  
Narrow Gaps ◽  
Helical Electrode

Abstract Micro-hole fabrication at a high speed and accuracy of machining while maintaining high surface quality is challenging. A core difficulty is the removal of the products of machining from extremely narrow gaps. To solve this problem, this study proposes an approach that combines high-speed electrical discharge machining (EDM) with electrochemical machining (ECM) by using a helical tube electrode with matched internal and external flushing. During high-speed electrical discharge drilling, matching the internal flushing with the clockwise rotation of the helical electrode can help remove debris from the bottom of the blind hole. During ECM, matching the external flushing with the anticlockwise rotation of the helical electrode can improve the flow of electrolyte in the gap. First, the flow field was simulated to show that matching the internal and external flushing of the helical electrode can enhance the flow of the medium and reduce particle concentration in extremely narrow gaps. Second, a series of experiments were conducted to verify that the taper of the hole and the surface quality of its wall can be improved by using the helical tube electrode. Finally, an experiment was carried out to optimize the machining parameters, and yielded a minimum taper of 0.008 at a speed of rotation of 460 rpm, and pressures of internal and external flushing of 9 MPa and 4 MPa, respectively.

Study on Parameters Optimization in Ultra-Precise Processing of Germanium Substrate

2009 ◽  
Vol 69-70 ◽  
pp. 442-445 ◽  
Author(s):  
Xun Lv ◽  
Ju Long Yuan ◽  
Yang Yu Wang ◽  
Qian Fa Deng
Keyword(s):  
Surface Quality ◽  
Parameters Optimization ◽  
Machining Parameters ◽  
Rough Machining ◽  
Process Technology ◽  
Improve Efficiency ◽  
Finish Machining ◽  
Good Surface ◽  
Germanium Substrate ◽  
Ultra Precision

To improve efficiency in ultra-precision lapping germanium (Ge) substrate, a new ultra-precise process technology is introduced in this paper. Two steps ultra-precise process were semi bonded abrasive lapping in rough machining, and CMP process in finish machining. A good surface quality workpiece was obtained in semi bonded abrasive lapping process efficiently. Several machining parameters were compared and applied. After CMP process, the mirror-like surface of Ge substrate was obtained.

Experimental investigations on ultra-precision machining of polycarbonate and related issues

2020 ◽  
pp. 251659842093849
Author(s):  
Vinod Mishra ◽  
Rohit Sharma ◽  
Kuldeep Mahajan ◽  
Jayant Kumar ◽  
Neha Khatri ◽  
...  
Keyword(s):  
Surface Quality ◽  
Cutting Temperature ◽  
Precision Machining ◽  
Experimental Investigations ◽  
Machining Parameters ◽  
Optical Components ◽  
Good Surface ◽  
Ultra Precision ◽  
Deterministic Processes ◽  
Glass Optics

Optical plastic lenses are progressively substituting glass optics due to their lightweight and low costs. Polycarbonate (PC) is considered as one of the leading optical materials due to its good mechanical and optical properties. Ultra-precision machining is the most suited process to develop PC optical components. Nevertheless, ultra-precision machining is considered as one of the deterministic processes to ensure the surface quality required for optical components. However, it is important to understand the behavior of the material during each stage of manufacturing. PC offers many challenges during its processing to achieve the nanometric finish and sub-micron form accuracies. In this article, the various issues of PC machining are discussed through experimental investigations. The effect of machining variables, that is, machining parameters, cutting temperature, and vacuum clamping on surface quality is studied. The results show the importance of the selection of optimum conditions for machining PC with good surface quality. The PC optical component is developed with surface finish ( Ra) 18.1 nm and profile accuracies ( Pv) of 0.116 µm. The study is helpful to understand the various issues involved in PC machining and hence to minimize their effects on surface quality.

Precise-Micro PECM System and its Applications Combining Synchronizing Ultrasonical Vibration

2011 ◽  
Vol 295-297 ◽  
pp. 834-839 ◽  
Author(s):  
Yong Wei Zhu ◽  
Xing Lei Miao ◽  
Chao Feng Zhang
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Electrical Discharge Machining ◽  
New Technology ◽  
Electrochemical Machining ◽  
Electrical Circuit ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Micro Machining ◽  
High Productivity

The micro-PECM (Pulse Electrochemical Machining) combining synchronous ultrasonic vibration is proposed as a new technology for to solve the difficulty machining problems of conductive hard and tough materials. The feasibility of micro-PECM combining synchronous ultrasonic vibration is studied. The synchronous way is analyzed; the synchronous electrical circuit is designed and made. The synchronous electrochemical micro-machining system combining ultrasonical vibration are built and improved，which machining parameters can be adjusted in a wide ranges, and the synchronous target of the ultrasonical vibration with the voltage of micro-PECM can be realized. The micro-machining electrodes are manufactured in different sections and sizes by combined electrical discharge machining. The mechanism tests of micro-PECM are carried, which kentaniums （YBD151、YG8）and stainless steel are machined and the results are analyzed and discussed. Contrast with the single micro-USM, the micro-PECM combining ultrasonic vibration has high productivity, good machining accuracy and surface quality; furthermore, its cathode wastage is low. The micro-PECM combining synchronous ultrasonic vibration has the best machining precision and surface quality.

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