An analysis of the tool electrode working mechanism of grinding-aided electrochemical discharge machining of MMCs

2018 ◽  
Vol 99 (5-8) ◽  
pp. 1369-1378 ◽  
Author(s):  
Jiangwen Liu ◽  
Zhibiao Lin ◽  
Taiman Yue ◽  
Zhongning Guo ◽  
Shuzhen Jiang
Keyword(s):  
Tool Electrode ◽  
Working Mechanism ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge

scholarly journals Influence of Different Tool Electrode Materials on Electrochemical Discharge Machining Performances

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1077
Author(s):  
Islam Md. Rashedul ◽  
Yan Zhang ◽  
Kebing Zhou ◽  
Guoqian Wang ◽  
Tianpeng Xi ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Electrical Conductivity ◽  
Electrode Materials ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Channels

Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.

Electrochemical discharge machining: A review on preceding and perspective research

2018 ◽  
Vol 233 (5) ◽  
pp. 1425-1449 ◽  
Author(s):  
Manpreet Singh ◽  
Sarbjit Singh
Keyword(s):  
Film Formation ◽  
Machining Process ◽  
Future Research ◽  
Work Piece ◽  
Tool Electrode ◽  
Conductive Materials ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Channels ◽  
Micro Holes

Electrochemical discharge machining has been proved to be efficient micro-machining process and significantly used for the machining of non-conductive materials. The miniaturized products have gained advantages in Lab-on-a-chip devices and microelectromechanical system because of advancement in technology. The challenge to produce micro features has been suitably addressed by electrochemical discharge machining and emerged as potential contender in generating micro holes and micro channels on electrically non-conductive materials. This article includes state-of-art review on different domains of electrochemical discharge machining, which includes work piece, electrolyte, behaviour of tool electrode, gas film formation, machining quality along with recent hybridizations in electrochemical discharge machining process. The conclusion focuses or summarizes the future research trends for enhancement of electrochemical discharge machining efficiency and tackles problems encountered in machining.

Experimental Investigation of Drilling Incorporated Electrochemical Discharge Machining

2014 ◽  
Author(s):  
Baoyang Jiang ◽  
Shuhuai Lan ◽  
Jun Ni
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Hole Drilling ◽  
Tool Electrode ◽  
Drilling Process ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Drilling

Electrochemical discharge machining (ECDM) is a non-conventional micromachining technology, and is highlighted for non-conductive brittle materials. However, the outcomes of ECDM have many restrictions in application due to limitations on efficiency, accuracy, and machining quality. In this paper, a drilling incorporated ECDM process is presented and analyzed to enhance material removal rate in ECDM drilling process. Incorporating micro-drilling into ECDM significantly increases the rate of material removal, especially in deep hole drilling. As fundamentals of the machining process, material removal mechanisms have been investigated to account for the increment in material removal rate by incorporating micro-drilling. Vibration of tool electrode, induced by a piezo-actuator, was introduced to further enhance material removal rate. Quantitative studies were conducted to determine the appropriate process parameters of drilling incorporated ECDM with tool vibration.

scholarly journals Influence of Electrochemical Discharge Machining Parameters on Machining Quality of Microstructure

2021 ◽  
Author(s):  
Douyan Zhao ◽  
Hao Zhu ◽  
zhaoyang zhang ◽  
Kun Xu ◽  
Jian Gao ◽  
...  
Keyword(s):  
Bottom Surface ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Layer By Layer ◽  
Machining Parameters ◽  
Processing Efficiency ◽  
Factors Affecting ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Power Frequency

Abstract As a nontraditional processing technology, Electrochemical discharge machining (ECDM) can precisely process glass and engineering ceramics. This technology has proven to be a potential process for glass 3D microstructure. However, the key to expanding the application of ECDM is how to improve machining accuracy. This research conducted micro-hole and microgroove machining. The influence of power voltage and frequency on hole processing efficiency, hole entrance diameter and hole limit depth explored. We considered four factors affecting ECDM–the voltage and frequency of the pulse power supply, the tool electrode feed rate, and the rotation speed. We studied their influence on the roughness of the microgrooves. The results show that machining efficiency, entrance diameter and limit depth of micro-holes increased with the increase in voltage, but decreased with the increase in power frequency. The results show that the roughness of microgrooves has an obvious positive correlation with the power voltage, while it had an obvious negative correlation with the power frequency and the electrode speed. The bottom surface roughness of microgrooves can be as small as 0.605µm. Various complex 3D microstructures on the glass surface by layer-by-layer method, which proved the great potential of ECDM.

Review On Recent Advances, Research Trends and Gas Film in Electrochemical Discharge Based Micro-Machining (ECDM)

2020 ◽  
Author(s):  
Viveksheel Rajput ◽  
Mudimallana Goud ◽  
N M Suri
Keyword(s):  
Tool Electrode ◽  
Micro Machining ◽  
Chemical Dissolution ◽  
Thermal Heating ◽  
Electrical Parameters ◽  
Machining Performance ◽  
Thermal Cracks ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Input Parameters

Abstract Electrochemical discharge machining (ECDM) is distinguished as a novel process that involves thermal heating and chemical dissolution for the micro-machining of "difficult-to-machine" materials like ceramics, quartz. This paper comprehensively reviews the study on gas film, the effect of various input parameters on ECDM performance, such as electrical parameters, electrolyte parameters, and tool electrode parameters, are also likewise discussed. Moreover, a summarized report on thermal modeling, gas film, discrete input parameters, hybridization, and variants in the ECDM process are also provided in a lucid manner. Based on the review, it is concluded that the machining performance of the ECDM process especially in terms of MRR, roughness, tool wear, and thermal cracks are strongly influenced by the input parameters. The formation of the gas film induces variable machining features that can be controlled by altering the machining conditions. Additionally, the paper highlights the future areas that may leads to improve the overall machining performance of the ECDM process.

scholarly journals Effects of Helical Tube Electrode Structure on Mixed Machining Product Transfer in Micro-Machining Channel during Tube Electrode High-Speed Electrochemical Discharge Machining

Micromachines ◽  
2019 ◽  
Vol 10 (10) ◽  
pp. 634 ◽  
Author(s):  
Yan Zhang ◽  
Chen Wang ◽  
Yu Wang ◽  
Lei Ji ◽  
Jian Tang ◽  
...  
Keyword(s):  
Flow Field ◽  
High Speed ◽  
High Efficiency ◽  
Helical Structure ◽  
Tool Electrode ◽  
Electrode Structure ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Tube Electrode ◽  
Processed Products

In tube electrode high-speed electrochemical discharge machining (TSECDM), mixed products are constantly produced in the narrow machining gap by simultaneous discharge erosion and electrochemical dissolution. For the high-efficiency removal of these products from the machining gap, a tool electrode with an optimized helical structure was utilized in TSECDM in this study. Firstly, the concentration distributions of the processed products in the machining gap using tube electrode tools with three typical helical structures were studied through the simulation of solid–liquid coupling; this showed that a trapezoidal helical structure benefited the reduced accumulation of products in grooves and the effective removal of products from the machining gap. Secondly, the main geometric parameters of the trapezoidal helical structure, including the helical groove depth, pitch, and tooth angle, were optimized by gap flow-field simulation to enhance the removal effect on processed products. Finally, it was verified that the trapezoidal helical electrode showed a definitive and significant advantage over the ordinary cylindrical electrode in effectively removing processed products from the machining gap by the comparison of flow-field simulations and actual machining experiments.

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