scholarly journals An Investigation of Ultrasonic-Assisted Electrochemical Machining of Micro-Hole Array

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1615
Author(s):  
Zhe-Yong Shen ◽  
Hai-Ping Tsui
Keyword(s):  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Pressure Difference ◽  
Hole Drilling ◽  
Periodic Pressure ◽  
Ultrasonic Assisted ◽  
Micro Hole ◽  
Pulse Off Time ◽  
Off Time ◽  
Diagonal Length

This paper uses an ultrasonic vibration-integrated array electrode for 301 stainless steel micro-hole drilling. The influence of machining parameters such as ultrasonic vibration amplitude, working voltage, pulse-off time and electrode feed rate on different processing characteristics are discussed. The experimental results show that the ultrasonic-assisted electrode array vibrating generates a periodic pressure difference for the electrolyte. The periodic pressure difference forms a pumping effect and a cavitation effect. The two effects can effectively renew the electrolyte in the machining gap and discharge the reaction product, gas and reaction heat from the gap. Machining speed can be increased by over 500% when the ultrasonic amplitude increases from 0.94 μm to 2.87 μm. Micro-hole drilling with the optimum experimental parameter combination of ultrasonic amplitude 2.87 μm, working voltage 11 V, pulse-off time 50 μs and electrode feed rate 5 μm/s can result in a minimum average diagonal length and a smaller amount of variation in diagonal length. It also improves the inlet and outlet taper angle of micro-holes.

scholarly journals Empirical Investigations during WEDM of Ni-27Cu-3.15Al-2Fe-1.5Mn Based Superalloy for High Temperature Corrosion Resistance Applications

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3470 ◽  
Author(s):  
Vivek Aggarwal ◽  
Catalin Iulian Pruncu ◽  
Jujhar Singh ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov
Keyword(s):  
Feed Rate ◽  
Research Work ◽  
Spark Gap ◽  
Nickel Copper ◽  
Cutting Rate ◽  
Response Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Monel K-500, a nickel–copper based alloy, is a very hard and tough material. Machining of such hard and tough materials always becomes a challenge for industry and this has been resolved by wire electric discharge machining (WEDM), a popular non-conventional machining method used for machining tough and hard materials having complex shapes. For the first time reported in this present research work is an experimental investigation executed on Ni-27Cu-3.15Al-2Fe-1.5Mn based superalloy using WEDM to model cutting rate (CR) and surface roughness (SR) using response surface methodology (RSM). The process parameters have been selected as pulse-on time, pulse-off time, spark-gap voltage and wire-feed rate. Experiments have been planned according to the central composite design (CCD). The results show that pulse-on time has a direct effect on CR while the pulse-off time has a reverse effect. The CR increases as pulse-on time increases, and decreases as pulse-off time increases. SR increases as pulse-on time increases, and decreases as pulse-off time increases. Furthermore, increase in spark-gap voltage decreases CR and SR both. The wire feed-rate has a negligible effect for both the response parameters. The optimized values of CR and SR achieved through multi-response optimization are 2.48 mm/min and 2.12 µm, respectively.

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.

scholarly journals The analysis of material removal rate of WEDM miniature gears

2021 ◽  
Vol 41 (3) ◽  
Author(s):  
Ashish Goyal ◽  
Vyom Singh ◽  
Abhishek Patel
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spur Gear ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Gear fabrication in wire electrical discharge machining (WEDM) plays an important role in manufacturing industries. This paper describes the analysis and optimization of process parameters for the fabrication of spur gear on brass spur gear on brass workpiece (10cmx15cmx6mm) material by wire EDM process. The experiments were performed by using the design of experiment (DoE) approach and the material removal rate (MRR) was analyzed by response surface methodology technique. The effect of input parameters i.e. pulse on time, pulse off time and feed rate on MRR has been investigated. The surface geometry of the gears has been analysed by the Scanning Electron Microscopy (SEM). This study found that 0.4 μs for pulse on time, 60 μs for pulse-off time and 6 mm/min for feed rate provides improved material removal rate. The analysis of variance shows that pulse on time and feed rate are the significant parameters for the wire EDM process. The SEM image exhibits the capability of WEDM to machined miniature gear with a uniform distribution of regular-shaped craters and defect-free flank surface.

Research on the Topography Feature of the Diamond Grinding Wheel under Elliptical Ultrasonic Assisted Dressing with Diamond Stylus

2010 ◽  
Vol 42 ◽  
pp. 126-130
Author(s):  
Quan Cai Wang ◽  
Nan Fang He ◽  
Guo Fu Gao ◽  
Bo Zhao
Keyword(s):  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Grinding Wheel ◽  
Diamond Grinding Wheel ◽  
Diamond Grinding ◽  
Abrasive Grain ◽  
Ultrasonic Assisted

In this paper, topography feature of the diamond grinding wheel under the diamond stylus elliptical ultrasonic vibration assisted dressing was studied experimentally. The results indicate that: the increase in dressing power of elliptical ultrasonic vibration will result in the increase in amplitude, and that can increase abrasive protrusion height of the dressing grinding wheel, and also increase the depth of chip pocket. With the increase of feed rate, surface peak and valley values of elliptical ultrasonic vibration dressing grinding wheel increase, that is the average protrusion height of abrasive grain increases. With the increase of dressing depth, surface peak and valley values of elliptical ultrasonic vibration dressing grinding wheel increases, while the number of static effective abrasive grain reduces. In comparison with the ordinary dressing grinding wheel, elliptical ultrasonic assisted dressing in the same parameters can bring about more static effective abrasive grain , more uniform abrasive distribution, a higher abrasive protrusion height and more chip space.

High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM

CIRP Annals ◽  
2009 ◽  
Vol 58 (1) ◽  
pp. 213-216 ◽  
Author(s):  
Z.Y. Yu ◽  
Y. Zhang ◽  
J. Li ◽  
J. Luan ◽  
F. Zhao ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
High Aspect Ratio ◽  
Hole Drilling ◽  
Micro Edm ◽  
Micro Hole

Multi-Feature Optimization of WEDM for Ti-6Al-4V by Applying a Hybrid Approach of Utility Theory Integrated With the Principal Component Analysis

2018 ◽  
Vol 5 (1) ◽  
pp. 32-51 ◽  
Author(s):  
Sachin Ashok Sonawane ◽  
M.L. Kulkarni
Keyword(s):  
Principal Component Analysis ◽  
Feed Rate ◽  
Utility Theory ◽  
Hybrid Approach ◽  
Principal Component ◽  
Feature Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

In this study, multi-feature optimization is performed using a hybrid approach of utility theory (UT) combined with the principal component analysis (PCA) during wire electrical discharge machining (WEDM) of Ti-6Al-4V. Taguchi's L27 orthogonal collection is used to evaluate the effects of the pulse on time, pulse off time, peak current, servo voltage, wire feed rate and cable tension on surface roughness (SR), overcut and metal removal rate (MRR). The utility concept is employed to turn the multi-feature problem into a distinct equivalent feature called as overall efficiency index (OEI). Optimal sets of governing parameters using a hybrid approach are established as the pulse on time 114 machine unit, pulse off time 55 machine unit, servo voltage 20 volts, peak current 190 Amp., wire feed rate 5 m/min and cable tension 2 device unit. Scanning Electron Microscopic (SEM) analysis of cut surfaces shows a lump of debris, microvoids, micro-cracks, and large dark craters at high values of the pulse on time.

Study on Machining Characteristics of Ultrasonic Vibration Assisted Micro-EDM

2012 ◽  
Vol 217-219 ◽  
pp. 2163-2166 ◽  
Author(s):  
Tomohiko Ichikawa ◽  
Wataru Natsu
Keyword(s):  
Ultrasonic Vibration ◽  
Machining Process ◽  
Hole Drilling ◽  
Micro Edm ◽  
Discharge Energy ◽  
Machining Speed ◽  
Micro Hole ◽  
Short Circuits ◽  
Small Discharge ◽  
Machining Characteristics

The existence of debris in the inter-electrode area in micro-EDM interrupts the machining process. Applying ultrasonic vibration to the machining fluid helps circulate the machining fluid and remove the debris from the gap area, and thus reduce short-circuits and abnormal discharges. In this study, the effect of applying ultrasonic vibration to machining fluid in micro-EDM was experimentally investigated. It was found that a significant increase in the machining speed was realized by applying ultrasonic vibration. Also, with the vibration of the machining fluid, micro-hole drilling with ultra-small discharge energy became possible.

Experimental Study on Ultrasonic Vibration Drilling of Titanium Alloy Micro-Hole

2012 ◽  
Vol 588-589 ◽  
pp. 1877-1880 ◽  
Author(s):  
Zhan Feng Liu ◽  
Huan Chang Zhang
Keyword(s):  
Titanium Alloy ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Hole Drilling ◽  
Drilling Process ◽  
Basic Principles ◽  
Actual Structure ◽  
Tc4 Titanium Alloy ◽  
Micro Hole ◽  
Vibration Drilling

Through the analysis of the basic principles of vibration drilling and vibration drilling process, in the drilling device and the cutting parameter sides , combined with the actual structure of the workpiece as well as the ultrasonic vibration drilling processing methods to elaborate, using the ultrasonic vibration drilling device to carry out the TC4 titanium alloy micro-hole drilling test. The test prove that selecting reasonable cutting parameters can solve the problem of drillingTC4 titanium alloy micro-hole that size is Φ1.5mm × 12mm , fully reflects the superiority of the ultrasonic vibration drilling. A new method was afforded for titanium alloy micro-hole drilling.

An Experimental Investigation of Ultrasonic Assisted Grinding in DOE Approach

2012 ◽  
Vol 565 ◽  
pp. 129-134 ◽  
Author(s):  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Kyung Hee Park ◽  
Young Jae Choi ◽  
Seok Woo Lee ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotation Speed ◽  
Grinding Force ◽  
Machining Parameters ◽  
Grinding Forces ◽  
Ultrasonic Assisted Grinding ◽  
Ultrasonic Assisted ◽  
Conventional Grinding

In this work, grinding test was performed in terms of machining parameters, such as grinding speed, feed rate, etc., in order to study effect of ultrasonic vibration in grinding. The design of experiment (DOE) approach was used for an optimal condition of ultrasonic assisted grinding, which can minimize the grinding forces. In DOE, ultrasonic amplitude power, feed rate, and rotation speed of spindle were chosen as the major machining factors. The grinding forces were measured and compared between the conventional grinding and ultrasonic assisted grinding. From the experiment, it was found that the grinding forces decreased as the ultrasonic vibration power and the rotation speed of spindle increased while the grinding force was reduced as the feed rate increased. In addition, regression model was formulated for obtaining optimal grinding condition.

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