Fabrication of deep and small holes by synchronized laser and shaped tube electrochemical machining (Laser-STEM) hybrid process

2019 ◽  
Vol 105 (5-6) ◽  
pp. 2721-2731 ◽  
Author(s):  
Yufeng Wang ◽  
Feng Yang ◽  
Guangyi Zhang ◽  
Wenwu Zhang
Keyword(s):  
Electrochemical Machining ◽  
Hybrid Process ◽  
Shaped Tube ◽  
Small Holes

Study of Pulse Electrochemical Machining Performance of Deep-Small Hole on Nickel-Based Alloy

2011 ◽  
Vol 204-210 ◽  
pp. 1830-1834
Author(s):  
Zhao Long Li ◽  
Shi Chun Di
Keyword(s):  
Base Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Math Model ◽  
Technical Parameters ◽  
Pulse Electrochemical Machining ◽  
Small Holes

The method of machining deep hole on Ni-base alloy which can tolerant high temperature by pulse electrochemical machining has been proposed in this paper. Five technical parameters are discussed on the effect of mass removal rate of machining process. Establish a dynamic math model, and analyze the effect of process parameters on the mass material removal rate of deep small holes. Machining accuracy of deep small holes was analyzed.

Electrical Discharge/Electrochemical Hybrid Machining Based on the Same Machine and Tool Electrode

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Ryoichiro Kishi ◽  
Jiwang Yan
Keyword(s):  
Electrical Discharge ◽  
Surface Defects ◽  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Hybrid Process ◽  
Tool Electrode ◽  
Alignment Error ◽  
Rapid Fabrication ◽  
Finishing Process

Abstract Electrical discharge machining (EDM) causes surface defects such as resolidified layer and microcracks, and a finishing process is usually needed to remove these defects. In this paper, a hybrid process was proposed where electrochemical machining (ECM) was performed as a finishing process after EDM using the same tool electrode on the same machine. By using two kinds of disk-type rotary electrodes, rectangular grooves and grooves with convex inner structures were fabricated. Surface topography were investigated by using scanning electron microscope (SEM), energy dispersive X-ray spectrometry (EDX), and laser-probe surface profilometer. The material removal mechanism of resolidified layers was clarified. The surface roughness of the rectangular groove was improved from 3.82 μm Ra to 0.86 μm Ra after ECM. Electrode rotation was effective for flushing electrolytic products when fabricating inner structures. As there is no need for exchanging tools and machines, tool alignment error can be prevented and productivity can be improved. Therefore, the proposed EDM/ECM hybrid process contributes to rapid fabrication of microscale products with high surface integrity.

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.

Rotary Combined Ultrasonic and Electrochemical Machining Device of Small Holes and its Test Study

2013 ◽  
Vol 584 ◽  
pp. 54-59
Author(s):  
Ze Xiang Liu ◽  
Min Kang ◽  
Xiu Qing Fu
Keyword(s):  
Electrochemical Machining ◽  
Future Research ◽  
Test Study ◽  
The Future ◽  
Small Holes

Discussing the technology of small holes processing and the development of the combined ultrasonic and electrochemical machining, the technology of combined ultrasonic and electrochemical Machining was studied and its device was designed. By the preliminary tests, the impacts of various factors on the processing of small holes by combined ultrasonic and electrochemical machining were analyzed and some problems were found, which provided a basis for the future research.

Research on Electrochemical Machining of Deep Small Holes with Positive and Negative Pulse Power

2021 ◽  
Vol 14 ◽  
Author(s):  
Zhaolong Li ◽  
Bingren Cao
Keyword(s):  
Power Supply ◽  
Pulse Width ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Negative Pulse ◽  
Mass Removal ◽  
Nickel Based Alloy ◽  
Accuracy And Stability ◽  
Small Holes

Background: High-temperature alloy such as nickel-based alloy has become the main material for core components such as aero engines due to their high strength and good toughness. Therefore, it is of great significance to study how to improve the machining accuracy and stability of electrochemical machining (ECM) of deep small holes on the nickel-based alloy. The instantaneous high-density current during the pulse width of pulse ECM is beneficial to the dissolution of metal workpieces. Many experts and scholars have studied the pulse ECM of deep small holes. Objective: The purpose of this article is to propose and design a Positive And Negative Pulse (PANP) power supply to study the accuracy and stability of ECM of deep small holes on nickel-based alloys. Methods: First of all, an H-bridge composed of four MOSFET switches is designed to achieve PANP output in the main circuit of the power supply. Then, this paper studies the influence of the ratio of positive and negative pulses on short circuits, the influence of the ratio of positive and negative pulses on the mass removal rate, and the influence of the electrolyte concentration and pulse width on the mass removal rate. Finally, according to the obtained optimal parameters, the influence of electrolyte pressure on the average radial overcut of hole depth is analyzed. Results: The experimental results showed that the short-circuit frequency is reduced by more than 50% compared with non-negative pulse power supply; the ratio of positive and negative pulses, pulse width and electrolyte concentration and pressure were optimized by experiments to improve the mass removal rate of the workpiece and the average radial overcut of hole depth. Conclusion: The designed PANP power supply can improve the machining accuracy and stability of ECM of deep small holes on nickel-based alloys.

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.

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