scholarly journals Investigating Tungsten Carbide Micro-Hole Drilling Characteristics by Desktop Micro-ECM with NaOH Solution

Micromachines ◽  
2018 ◽  
Vol 9 (10) ◽  
pp. 512 ◽  
Author(s):  
Yung-Yi Wu ◽  
Dong-Yea Sheu
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Low Cost ◽  
Machining Process ◽  
Hole Drilling ◽  
Tungsten Carbides ◽  
Micro Ecm ◽  
Micro Holes ◽  
Micro Hole ◽  
Drawing Dies

Due to their hardness and low tool wear, tungsten carbides are widely used in industrial applications, such as spray nozzles, wire drawing dies and spinning nozzles. However, there is no conventional machining process that is capable of fabricating micro-holes, slots and complicated shapes in tungsten carbide. In this study, a low-cost desktop micro electro-chemical machining (ECM) was developed to investigate the characteristics of tungsten carbide micro-hole drilling. The performance parameters of the machining conditions by desktop micro-ECM, such as the machining time, material removal rate, relative tool wear rate, surface quality and dimensional accuracy, were also investigated in this study. The experimental results demonstrate that the low-cost desktop micro-ECM could fabricate micro-holes in the tungsten cemented carbide (WC-Co) workpiece.

Micro-Hole Drilling on Ti6Al4V by Sequential Electro-Micro-Machining (SEMM) Approach

2020 ◽  
Vol 19 (03) ◽  
pp. 499-516
Author(s):  
R. M. Tayade ◽  
B. Doloi ◽  
B. R. Sarkar ◽  
B. Bhattacharyya
Keyword(s):  
Titanium Alloy ◽  
Research Work ◽  
Machining Process ◽  
Hole Drilling ◽  
Thick Sheet ◽  
Micro Machining ◽  
Taper Angle ◽  
Micro Holes ◽  
Micro Hole ◽  
Sequential Combination

This research work explores the feasibility of drilling micro-holes on Ti6Al4V by applying a sequential electro-micro-machining process. A novel sequential combination of micro-electrochemical discharge machining ([Formula: see text]ECDM) and micro-electro-chemical machining ([Formula: see text]ECM) is applied for drilling micro-hole in titanium alloy (Ti6Al4V). The machining of titanium alloy by a [Formula: see text]ECDM process is a challenging task and not reported yet. Therefore, the feasibility of machining of Ti6Al4V by [Formula: see text]ECDM using various combinations of electrolytes has been studied. The best-suited electrolyte for drilling by [Formula: see text]ECDM was selected by analyzing the hole depth, radial overcut, hole taper angle and the minimum time required to drill through holes in a 400[Formula: see text][Formula: see text]m thick sheet of titanium alloy. The [Formula: see text]ECDM process produces micro-holes rapidly but it consists of recast layer, micro-cracks, and heat affected zone, etc. The surface characteristics of a [Formula: see text]ECDMed hole were improved by applying [Formula: see text]ECM process subsequent to the [Formula: see text]ECDM process. The sequential combination of [Formula: see text]ECDM shaping and [Formula: see text]ECM finishing results in improved dimensional accuracy, machining depth, taper angle, and surface quality of the hole produced by sequential micro-machining process.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Experimental Investigation Into Sequential Micro Machining (SMM) for Micro Hole Drilling on SS–304

2019 ◽  
Vol 9 (4) ◽  
pp. 1-16
Author(s):  
Raju Mahadeorao Tayade ◽  
Biswanath Doloi ◽  
Biplab Ranjan Sarkar ◽  
Bijoy Bhattacharyya
Keyword(s):  
Xrd Analysis ◽  
304 Stainless Steel ◽  
Hole Drilling ◽  
Machining Parameters ◽  
Micro Machining ◽  
Machining Processes ◽  
Taper Angle ◽  
Micro Holes ◽  
Micro Hole ◽  
Ss 304

Sequential micro machining (SMM) is a strategy of machining applied for micro-part manufacturing. Due to the finding of new sequential machining combinations, the authors have presented a novel combination of micro-ECDM (µECDM) drilling and micro-ECM (µECM) finishing for producing micro-holes in SS-304 stainless steel. An experimental setup was developed indigenously to conduct both machining processes at one station. The sequential processes were employed with desirable machining parameters, during their individual execution. The most desirable parameter like machining voltage, for hole drilling by µECDM was decided by studying hole taper angle, radial overcut, etc. The µECDM generates a recast layer, to overcome the adverse effects of µECDM, with the µECM finishing applied subsequently. The experimental results of SMM indicate a reduction in hole taper angle, improved circularity, and better surface quality. The change of phase of material due to sequencing of µECDM and µECM processes was analyzed by an XRD analysis of SS-304.

Performance of Micro-Hole Drilling by Ultrasonic-Assisted Electro-Chemical Discharge Machining

2012 ◽  
Vol 445 ◽  
pp. 865-870 ◽  
Author(s):  
Meifal Rusli ◽  
Katsushi Furutani
Keyword(s):  
Ultrasonic Vibration ◽  
Removal Rate ◽  
Glass Plate ◽  
High Amplitude ◽  
Machining Process ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Conductive Materials ◽  
Electrolyte Level ◽  
Micro Hole

Electro-chemical discharge machining (ECDM) is one of nontraditional processes for micro-fabrication of non-conductive materials. A high applied voltage is preferable to form a gas film and to generate discharge in the film. However, accumulation of discharge heat often causes cracks of the surface because non-conductive materials have low heat conductivity. In this study, the effect of ultrasonic vibration and the electrolyte level on the performance of gravity-feed drilling by ECDM was investigated. Ultrasonic vibration was applied to a glass plate. A tungsten rod as a tool electrode was fed by gravity. Ultrasonic vibration changed the discharge behavior and improved electrolyte circulation. Although high amplitude ultrasonic vibration caused very dense and wide current pulses consistently during machining process, it decreased removal rate significantly. In addition, electrolyte levels affect single bubble size and the resistance in the electrolyte. Low electrolyte level will cause higher resistance, and higher temperature of the tool electrode and workpiece. A high bias current flew at a low electrolyte level without ultrasonic vibration. In this case, removal rate decreased and surface integrity was improved.

Optimizing the Electrical Discharge Drilling Process for High Aspect Micro Hole Drilling in Die Steel

2017 ◽  
pp. 120-141 ◽  
Author(s):  
Kamal Kumar
Keyword(s):  
Turbine Blades ◽  
High Strength ◽  
Hole Drilling ◽  
Drilling Process ◽  
Die Steel ◽  
Cooling Channels ◽  
Micro Holes ◽  
Grey Relational Grade ◽  
Micro Hole ◽  
Grey Relational

Electric discharge drilling (EDD) is a thermo erosion process used to produce holes in high strength materials for various applications such as fuel injector, medical devices, turbine blades cooling channels etc. In this chapter, high aspect micro holes are drilled in die steel (of thickness 15 mm) using tubular electrodes of diameter 500µm. Using Taguchi' design of experiment method, four process parameters namely electrode material, discharge current (Ip), pulse on time (Ton) and pulse-off time (Toff) are investigated and optimized for two performance characteristics namely drilling rate (DR) and electrode wear rate (EWR). DR and EWR are opposite in nature, i.e. DR is higher the better type of characteristics while EWR is lower the better type of characteristics. Using Grey relational analysis (GRA) along with Taguchi method, both the characteristics are optimized simultaneously. Through GRA, grey relational grade has been computed as a performance index for predicting the optimal parameters setting for multi machining characteristics.

scholarly journals Experimental Examination of Tool Wear During Turning of Ti-Grade 2 Alloy in Dry and Minimum Quantity Lubrication (MQL)

2019 ◽  
Vol 8 (12) ◽  
pp. 4768-4771
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Manufacturing Industry ◽  
Wear Behavior ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Depth Of Cut ◽  
Experimental Examination ◽  
Machine Material ◽  
Minimum Quantity

In any manufacturing industry cost and productivity are the major concerns to be taken care. There are several factors which can be used to control these factors and while it comes to machining tool wear plays a major role in deciding the productivity and cost of the machining process. Recently many studies have been done on the different alloys of titanium and it is found to be very useful and difficult to machine material as well. In this work turning of one of the titanium alloys is used to study the tool wear behavior during dry and minimum quantity lubrication (MQL) machining conditions. In the current work tungsten carbide (WC) insert is used for machining process. After the machining Taguchi’s analysis is used to analyze the results obtained after the machining. In this work spindle speed, feed, and depth of cut are taken as the input parameters along with the machining condition. From the results it is found that MQL provides the better results to minimize the tool wear

Fabrication of Micro Components to Silicon Wafer Using EDM Process

2006 ◽  
Vol 505-507 ◽  
pp. 217-222 ◽  
Author(s):  
Feng Tsai Weng ◽  
Chen Siang Hsu ◽  
Wen Feng Lin
Keyword(s):  
Tungsten Carbide ◽  
Silicon Wafer ◽  
Electrode Array ◽  
Copper Electrode ◽  
Silicon Wafers ◽  
Tool Electrode ◽  
Micro Holes ◽  
Micro Hole ◽  
Fine Tungsten ◽  
Edm Process

In this paper, the machining possibilities of silicon wafers by the EDM process are described. Micro components of silicon wafer were processed by EDM process. A fine tungsten carbide rod was machined as tool electrode for EDM process. Performance was investigated utilizing serious experiments. Micro hole was process with the fine electrode using EDM drilling. Micro slots were also processed on the surface of a silicon plate by a copper section electrode. The surface roughness of the silicon wafers in the EDM process was investigated. Array-micro-hole was machined by a tungsten carbide multi-electrode. Array micro holes on the coaxial circle were processed by a graphite-copper electrode of Dia.0.45mm. Batch production technology for economical EDM machining of micro holes were proposed.

Study on Vibration Grinding Deburring Finishing Process

2011 ◽  
Vol 211-212 ◽  
pp. 634-637
Author(s):  
Peng Zhang ◽  
Xing Yu Guo ◽  
Shao Fu Shan ◽  
Chen Ge Wu
Keyword(s):  
Low Cost ◽  
Machining Process ◽  
Grinding Process ◽  
Process Technology ◽  
Simple Process ◽  
Finishing Process ◽  
Process System ◽  
Micro Hole

It is difficult to remove for burr, especially for micro-hole burr, so the vibration grinding process is put forward and adopted to remove burrs. The mechanism of vibration grinding deburring is analyzed, and the experiments of micro-hole deburring are done with the technology of vibration grinding. From the results of the experiments, the conclusion can be draw that this technology can remove the burrs effectively. The vibration grinding process has the features of simple process system, low cost, easy operating. The Vibration grinding process technology method can also be used to remove burrs of other machining process. It has more application value in practice.

The tool-wear characteristics of flexible printed circuit board micro-drilling and its influence on micro-hole quality

Circuit World ◽  
2016 ◽  
Vol 42 (4) ◽  
pp. 162-169 ◽  
Author(s):  
Lijuan Zheng ◽  
Chengyong Wang ◽  
Xin Zhang ◽  
Xin Huang ◽  
Yuexian Song ◽  
...  
Keyword(s):  
Tool Wear ◽  
Circuit Board ◽  
Hole Quality ◽  
Content Type ◽  
Wear Characteristics ◽  
Printed Circuit ◽  
Micro Holes ◽  
Micro Drilling ◽  
Micro Hole

Purpose Micro-holes are drilled and plated in flexible printed circuit boards (FPCs) for connecting circuits from different layers. More holes, with diameters smaller than 0.3 mm, are required to be drilled in smaller areas with flexible circuits’ miniaturization. The micro-hole quality of micro-drilling is one of the biggest issues of the flexible circuit manufacturers’ production. However, it is not easy to control the quality of micro-holes. The purpose of this study was to conduct research on the tool wear characteristics of FPC drilling process and its influence on micro-hole quality to improve the micro-hole quality of FPC. Design/methodology/approach The tool-wear characteristics of micro-drills after FPC drilling were observed. The influence of spindle speed, feed rate, number of drilled holes and entry board materials on tool-wear was analyzed. The hole qualities of FPC micro-drilling were measured and observed. The relationship between tool-wear and hole quality was analyzed. Findings The result showed that the tool-wear characteristics of FPC micro-drilling was similar to the tool-wear characteristics of rigid printed circuit board (RPC) micro-drilling. Abrasive wear occurred on both the main cutting edges and the chisel edges of micro-drills, even though there was no glass fiber reinforcing the cloth inside FPC. Resin adhesion was observed on the chisel edge. The influence of feed and number of drilled holes on tool-wear was significant. Tool-wear significantly influences the hole quality of FPC. Tool-wear will largely decrease the hole position accuracy of FPC micro-holes. Tool-wear will increase the thickness of PI nail heads and the height of exit burrs. Fracture was the main difference between tool wear of FPC and RPC micro-drilling. Resin adhesion of RPC was much more severe than FPC micro-drilling. Increasing the spindle speed properly may improve tool life and hole quality. Originality/value The technology and manufacturing of FPC has been little investigated. Research on micro-drilling FPC and research data is lacking so far. The micro-hole quality directly affects the reliability of FPC. Thus, improving the micro-hole quality of FPC is very important.

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