Effect of ultrasonic vibration object on machining performance of wire electrochemical micromachining

2021 ◽  
Author(s):  
Peng Tengfei ◽  
Wang Kan ◽  
Li Minghao ◽  
Liu Yong
Keyword(s):  
Ultrasonic Vibration ◽  
Electrochemical Micromachining ◽  
Machining Performance ◽  
Wire Electrochemical Micromachining

scholarly journals Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

Micromachines ◽  
2020 ◽  
Vol 11 (7) ◽  
pp. 698
Author(s):  
Siying Ling ◽  
Minghao Li ◽  
Yong Liu ◽  
Kan Wang ◽  
Yong Jiang
Keyword(s):  
Surface Roughness ◽  
Aspect Ratio ◽  
Ultrasonic Vibration ◽  
304 Stainless Steel ◽  
Electrochemical Micromachining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machined Surface ◽  
Wire Electrochemical Micromachining ◽  
Ultrasonic Assisted

Wire electrochemical micromachining (WECMM) technology is regarded a promising method to fabricate high aspect ratio microstructures on hard-to-machining materials, however, the by-product accumulation in the machining gap limits its application. In this paper, a new method called ultrasonic-assisted wire electrochemical micromachining (UA-WECMM) is proposed to improve the machining performance of WECMM. Firstly, a flow-field simulation in the machining gap was carried out; the results showed that the ultrasonic vibration of electrode can remarkably enhance the mass transport in the machining gap and improve the machining condition. Secondly, experiments were performed to confirm the effect of ultrasonic vibration, which illustrated that the vibration with proper amplitude can reduce the slit width and improve the morphology of machined surface. Moreover, the influence of other machining parameters were also discussed. Finally, a T-type micro connector with good surface roughness (Ra 0.286 μm) was fabricated on a 300-μm-thick 304 stainless steel workpiece and a micro gear (diameter: 3.362 mm; Ra: 0.271 μm) with an aspect ratio of 7 was fabricated on a 2-mm-thick workpiece. It is proved that the proposed ultrasonic-assisted wire electrochemical micromachining method has considerable potential and broad application prospects.

scholarly journals Electrochemical Microslot Machining by Ultrasonic-Vibration-Aided Electrolyte on Nitinol Wire

Processes ◽  
2021 ◽  
Vol 9 (10) ◽  
pp. 1752
Author(s):  
Jung-Chou Hung ◽  
Po-Jen Yang
Keyword(s):  
Ultrasonic Vibration ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Power Generator ◽  
Nitinol Wire ◽  
Wire Electrochemical Micromachining ◽  
Titanium Wire ◽  
Pulse Power Generator ◽  
Machining Characteristics

In this research, the main purpose was to study the applicability of a machining method on microscale medical-equipment manufacturing. The characteristics of wire electrochemical micromachining (WECMM) against NiTi 50-50 wire was investigated. The study utilized a tungsten wire 0.03 mm in diameter as an electrode to cut a fine slot into the nickel–titanium wire. In order to reach a high-precision WECMM finish, an ultrashort pulse power generator was used as a power source to minimize the stray current effect, thus improving the machining accuracy. During the process, various machining parameters were tested for their effects on machining characteristics. In addition, ultrasonic-vibration-aided WECMM was investigated to determine whether it benefited the machining characteristics. The experiment’s results showed that under such an experiment setting, microslots can be successfully manufactured. Furthermore, with the advance adjustment of experimental parameters, the machining accuracy was improved. Finally, a fine slot was manufactured under the optimum experiment parameters and aided by ultrasonic vibration.

scholarly journals Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 617
Author(s):  
Jing Li ◽  
Wanwan Chen ◽  
Yongwei Zhu
Keyword(s):  
Ultrasonic Vibration ◽  
Orthogonal Experiment ◽  
Spindle Speed ◽  
Machining Efficiency ◽  
Matrix Composites ◽  
Two Dimensional ◽  
Machining Performance ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Workpiece Vibration

Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.

Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM

2013 ◽  
Vol 675 ◽  
pp. 365-369 ◽  
Author(s):  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Hai Ping Tsui ◽  
Yuan Feng Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Dielectric Fluids ◽  
Edm Process

The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

Sign in / Sign up

Export Citation Format

Share Document