Predicting radial overcut in deep holes drilled by shaped tube electrochemical machining

2007 ◽  
Vol 39 (1-2) ◽  
pp. 47-54 ◽  
Author(s):  
D. S. Bilgi ◽  
R. Kumar ◽  
V. K. Jain ◽  
R. Shekhar
Keyword(s):  
Electrochemical Machining ◽  
Radial Overcut ◽  
Shaped Tube

On the Deep Small Hole Machining Method of Nickel-Based High-Temperature Alloy

2011 ◽  
Vol 199-200 ◽  
pp. 1874-1879
Author(s):  
Shi Chun Di ◽  
Zhao Long Li ◽  
Dong Bo Wei
Keyword(s):  
High Temperature ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Speed Ratio ◽  
High Temperature Alloy ◽  
Technological Parameters ◽  
High Quality ◽  
Radial Overcut ◽  
The Mathematical Model ◽  
Hole Machining

In this paper, a machining method of deep hole on the nickel-based high-temperature alloy using the pulse electrochemical machining is proposed. The effect of five technological parameters on the depth-averaged radial overcut of the hole to be machined in the machining process is discussed; then the mathematical model is built, and the effect of parameters on the overcut is illustrated. The speed ratio is determined to judge the quality and the processing performance of holes. The technological parameters adopted in the experiment, can be used to produce effectively high-quality hole of big proportion of depth to diameter on the nickel-based high-temperature alloy in the machining process.

scholarly journals Hole drilling and milling of magnetic alloys parts by shaped tube electrolytic machining

2018 ◽  
Vol 226 ◽  
pp. 03017
Author(s):  
Vladimir V. Glebov ◽  
Irina N. Danilenko ◽  
Ruslan I. Ratushinsky
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Electrochemical Machining ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Magnetic Alloys ◽  
Shaped Tube ◽  
Experimental Assembly ◽  
Micro Holes ◽  
New Research

In this research shaped tube electrolytic machining of drilling and milling of magnetic alloys parts and difficult-to-cut metals, steels and alloys is presented. New research made in the field of space, aviation, automobile, medical, computer and electronics, and others has created the need for small and fine holes with high aspect ratio in these materials. The primary investigations of ECM with the tubular tool electrode are presented. Compared with mechanical machining, shaped tube electrolytic machining (STEM) exhibits an advantage in producing micro-holes with a high aspect ratio and in producing the curved holes. In order to realize the process of electrochemical machining, experimental assembly with the shaped tube tool electrode has been designed and manufactured. Completed researches indicate that this tool electrode has a high potential to machine difficult-to-cut and brittle metals economically and efficiently.

Improving Performance of Laser and Shaped Tube Electrochemical Machining by Using Retracted Hybrid Tubular Tool Electrode

2021 ◽  
Author(s):  
yong yang ◽  
yufeng wang ◽  
Yujie Gui ◽  
Fuhui Shao ◽  
Yulei Li ◽  
...  
Keyword(s):  
Density Distribution ◽  
Electric Current ◽  
Current Density ◽  
Feeding Rate ◽  
Electrochemical Machining ◽  
Current Density Distribution ◽  
Electric Current Density ◽  
Tool Electrode ◽  
Shaped Tube ◽  
Tubular Electrode

Abstract The coaxial laser has been introduced to shaped tube electrochemical machining (STEM), referred to as Laser-STEM, to enhance the materials removal rate and precision. To address the issue of central residual formation during the Laser-STEM process, which limited the machining stability and feeding rate, the retracted hybrid tubular electrode was applied. The formation mechanisms and effects of the W-shaped central residual were analyzed. Simulation and experiments were conducted to study the impact of the retracted length of the tubular electrode. Simulation results showed that a retracted length of 1-1.5 mm of the inner low-refractive layer could improve the electric current density distribution homogeneity to remove the W-shaped central residual in the machining area. The electric current density distribution homogeneity in the machining zone has been decreased by 38% by utilizing the hybrid tubular electrode with a retracted length of 2.0 mm. With a proper retracted length, the laser coupling efficiency exceeded 74.5%. Hence, the retracted hybrid tubular electrode could act as both the tool electrode and optical waveguide in the Laser-STEM process. Experimental results proved that the machining efficiency and precision of Laser-STEM could be enhanced by utilizing the retracted hybrid tubular electrode. With the retracted length deg rising from 0 mm to 1.5 mm, the maximum feeding speed increased by 373%, and the machining precision was improved by 42.2%. The maximum feeding rate of 4.1 mm/min has been achieved using the retracted hybrid tubular electrode in the Laser-STEM process, which has been improved by 105%, compared with the available maximum feeding rate of the tubular electrode in the STEM process. Finally, the small holes with a diameter of 1.4 mm and an aspect ratio of 15 have been processed by Laser-STEM with the retracted hybrid tubular electrode.

scholarly journals Fabrication of Microgrooves by Synchronous Hybrid Laser and Shaped Tube Electrochemical Milling

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7714
Author(s):  
Yong Yang ◽  
Yufeng Wang ◽  
Yujie Gui ◽  
Wenwu Zhang
Keyword(s):  
Surface Roughness ◽  
Laser Power ◽  
Electrochemical Machining ◽  
Bottom Surface ◽  
Machining Accuracy ◽  
Machining Efficiency ◽  
Layer By Layer ◽  
Shaped Tube ◽  
Side Gap ◽  
Electrochemical Milling

The fabrication of deep microgrooves has become an issue that needs to be addressed with the introduction of difficult-to-cut materials and ever-increasing stringent quality requirements. However, both laser machining and electrochemical machining could not fulfill the requirements of high machining efficiency and precision with good surface quality. In this paper, laser and shaped tube electrochemical milling (Laser-STEM) were initially employed to fabricate microgrooves. The mechanisms of the Laser-STEM process were studied theoretically and experimentally. With the developed experimental setup, the influences of laser power and voltage on the width, depth and bottom surface roughness of the fabricated microgrooves were studied. Results have shown a laser power of less than 6 W could enhance the electrochemical machining rate without forming a deep kerf at the bottom during Laser-STEM. The machining accuracy or localization of electrochemicals could be improved with laser assistance, whilst the laser with a high-power density would deteriorate the surface roughness of the bottom machining area. Experimental results have proved that both the machining efficiency and the machining precision can be enhanced by synchronous laser-assisted STEM, compared with that of pure electrochemical milling. The machining side gap was decreased by 62.5% while using a laser power of 6 W in Laser-STEM. The laser-assistance effects were beneficial to reduce the surface roughness of the microgrooves machined by Laser-STEM, with the proper voltage. A laser power of 3 W was preferred to obtain the smallest surface roughness value. Additionally, the machining efficiency of layer-by-layer Laser-STEM can be improved utilizing a constant layer thickness (CLT) mode, while fabricating microgrooves with a high aspect ratio. Finally, microgrooves with a width of 1.79 mm, a depth of 6.49 mm and a surface roughness of 2.5 μm were successfully fabricated.

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