System Design and Kinematics Simulation of Electrochemical Machining Set-Up for Micro-Holes

2007 ◽  
Author(s):  
Jishun Jiang ◽  
Zhiyong Li
Keyword(s):  
Control Method ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Rectilinear Motion ◽  
Micro Machining ◽  
Technical Requirements ◽  
Kinematics Simulation ◽  
Wide Range ◽  
Micro Holes ◽  
Set Up

Electrochemical micro-machining (EMM) appears to be very promising as a future micro-machining technique, since in many areas of applications, it offers many advantages, which include excellent machining precision and control, high machining rate, perfect surface quality and a wide range of materials that can be machined, regardless of their strength and toughness. At present, electrochemical micro-machining has been applied in the production of some metal workpieces, such as micro-holes, micro-slots and complex 3D surfaces. In this paper, A new electrochemical micro-machining set-up for machining metal micro-holes has been developed. Double level mechanical structure has been applied as the main structure style, which has the advantage of excellent structure rigidity, compact framework dimension as well as perfect maneuverability and maintainability. The control system based on PLC control method has also employed to realize different motion styles for rotating axis, such as uniform velocity rectilinear motion, varying velocity rectilinear motion and cycle rectilinear motion and so on. In order to verify the reliability of this EMM set-up, some test works including static measurement, assembling interferences checking and kinematics simulation have been done. The simulation results demonstrate that the developed EMM set-up for manufacturing metal micro-holes is qualified and can satisfy the technical requirements of electrochemical micro-machining process.

Experimental Investigation for Characteristics of Localized Dissolution of Micro-Holes in Electrochemical Machining Aided by Ultrasonic Wave

2013 ◽  
Vol 567 ◽  
pp. 21-26 ◽  
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu ◽  
Li Li
Keyword(s):  
Experimental Investigation ◽  
Ultrasonic Wave ◽  
Electrochemical Machining ◽  
Wave Frequency ◽  
Micro Machining ◽  
Micro Holes ◽  
Micro Hole ◽  
Set Up

Electrochemical micro-machining (EMM) has become one of the main machining methods for production of miniaturized parts and components. Utilizing the developed EMM set-up, the effects of ultrasonic wave frequency on characteristics of localized dissolution and accuracy of micro-hole in EMM are investigated and evaluated. The experiment results demonstrate that the accuracy of micro-hole and characteristics of localized dissolution can become better with the increase of ultrasonic wave frequency. The accuracy of micro-hole machined by 26KHZ can improve about 30% than that by 16KHZ. Moreover, the ability of localized dissolution by 26KHZ can be increased about 27%-30%.

System Design and Low-Speed Kinematics Characteristic Analysis of Electrochemical Micro-Machining Equipment

2010 ◽  
Vol 458 ◽  
pp. 349-354
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu ◽  
Li Li
Keyword(s):  
Micro Machining ◽  
Characteristic Analysis ◽  
Vertical Column ◽  
Low Speed ◽  
Kinematics Simulation ◽  
Wide Range ◽  
Micro Holes ◽  
Simulation Results ◽  
Machining Rate ◽  
And Control

Electrochemical micro-machining (EMM) appears to be very promising as a future micro-machining technique, since in many areas of applications, it offers many advantages, which include excellent machining precision and control, high machining rate, perfect surface quality and a wide range of materials that can be machined, regardless of their strength and toughness. In the paper, a new style EMM equipment for micro-holes is presented. Double vertical column style structure is chosen as the main mechanical structure of the equipment, which has the advantage of excellent structure rigidity, compact framework dimension as well as good maneuverability and maintainability. In order to verify the reliability of this EMM equipment, some measurement works including static measurements, assembling interferences checking and kinematics simulation have been done. Furthermore, the low-speed kinematics characteristics of the developed EMM equipment are concentrated. The kinematics simulation results indicate that the developed EMM equipment can satisfy the requirements for low-speed motion and anti-interference characteristics of EMM process.

Fabrication of Micro-Structures by Micro-ECM

2009 ◽  
Vol 69-70 ◽  
pp. 229-233
Author(s):  
Ming Huan Wang ◽  
Qiao Fang Zhang ◽  
C.Y. Yao ◽  
Wei Peng
Keyword(s):  
Mathematical Model ◽  
Electrochemical Etching ◽  
Electrochemical Machining ◽  
Pulse Power ◽  
Micro Machining ◽  
Slot Milling ◽  
Micro Ecm ◽  
Micro Holes ◽  
Machining System ◽  
Micro Structures

The machining of materials on microscopic scales is considered to be great importance to a wide variety of fields. Electrochemical Micro-machining (EMM) appears to be promising to machine the micro-structures in future due to the material is dissolved at the unit of ion. This paper is focused on developing a micro electrochemical machining system in which the micro-structures such as micro-cylinder, multiple micro-electrodes, micro-holes and micro-slot were processed. The micro-electrodes were prepared in a precisely controlling the electrochemical etching process. Mathematical model controlling the diameters of electrodes was built up. Furthermore, the obtained micro-electrodes were selected as the cathode tool for micro holes drilling and micro-slot milling using pulse power in Micro-ECM.

Electrochemical Micro Machining of Stainless Steel with Voltage Pulses

2009 ◽  
Vol 69-70 ◽  
pp. 219-224
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Ying Huai Dong ◽  
Wan Sheng Zhao
Keyword(s):  
Stainless Steel ◽  
Oxide Layer ◽  
Electrochemical Machining ◽  
Electrolyte Composition ◽  
Machining Parameters ◽  
Micro Machining ◽  
Short Pulses ◽  
Is Research ◽  
Micro Holes ◽  
Voltage Pulses

The purpose of this paper is to study electrochemical micro machining (ECM) technology on stainless steel. The micro machining of stainless steel is difficult by electrochemical machining, especially in machining deep micro holes, because of an oxide layer formed on the surface. To machining stainless steel, HF is usually used in electrolyte to destabilize the oxide layer. In this paper, ECM of stainless steel by applying short pulses in less toxic and corrosive electrolyte is research. The influence of electrochemical machining parameters such as voltage, current, electrolyte composition to machine stainless steel was investigated. The results showed that the oxide layer can be reduced by adding chloride and complex.

PULSED ELECTROCHEMICAL MICRO MACHINING OF INVAR (FE-NI) FILM USING AN ELECTRODE ARRAY

2016 ◽  
Vol 40 (5) ◽  
pp. 739-747
Author(s):  
Kwang-Ho Chun ◽  
Seung-Geon Choi ◽  
Eun-Sang Lee
Keyword(s):  
Electrochemical Machining ◽  
Electrode Array ◽  
Laser Machining ◽  
Shadow Mask ◽  
Micro Machining ◽  
Thermal Change ◽  
Surface Burning ◽  
Change Characteristics ◽  
Micro Holes ◽  
Manufacturing Methods

Recently, invar (Fe-Ni) material has been applied to OLED shadow masks due to its thermal change characteristics and thermal expansion coefficient. The most widely used manufacturing methods for invar are etching and laser machining, but they have problems like non-machined areas generated by etching and surface burning in laser machining. For this reason, an alternative machining method is necessary. In this study, pulsed electrochemical machining (PECM) has been applied to fabricate an OLED shadow mask. PECM is a highly promising technology for shadow mask manufacturing because it can produce micro-scale and complex tapered holes in one process. A pilot experiment was carried out to find a suitable electrolyte for invar film, and an array of coated Ti electrodes was used to fabricate micro holes.

Micro-Hole Machined by Electrochemical Discharge Machining (ECDM) with High Speed Rotating Cathode

2011 ◽  
Vol 295-297 ◽  
pp. 1794-1799 ◽  
Author(s):  
Shao Fu Huang ◽  
Di Zhu ◽  
Yong Bin Zeng ◽  
Wei Wang ◽  
Yong Liu
Keyword(s):  
High Speed ◽  
Electrochemical Machining ◽  
304 Stainless Steel ◽  
Machining Accuracy ◽  
Micro Machining ◽  
Rotating Speed ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Holes ◽  
Micro Hole

Electrochemical discharge machining (ECDM), based on electrochemical machining (ECM) and electrodischarge machining (EDM), is an unconventional micro-machining technology. In this paper, with the use of water, the process of micro hole on ANSI 304 stainless steel machined by micro-ECDM with high speed rotating cathode is studied. The effects of machining conditions such as the cathode rotating speed and cathode diameter on the surface quality and accuracy of the shape are investigated. The results indicate that a relatively higher electrode rotating speed can improve the machining accuracy of the micro-holes and reduce the electrodes wear.

The technical development of titanium alloy surface process using electrochemical abrasive jet machining

2018 ◽  
Vol 70 (8) ◽  
pp. 1545-1551
Author(s):  
Feng Che Tsai ◽  
Yann Long Lee ◽  
Ju Chun Yeh
Keyword(s):  
Oxide Film ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Alloy Surface ◽  
Processing Efficiency ◽  
Content Type ◽  
Surface Machining ◽  
Abrasive Jet Machining ◽  
High Kinetic Energy ◽  
Set Up

Purpose This paper aims to develop an electrochemical abrasive jet machining (ECAJM) technology to investigate the surface machining effect of Ti-6Al-4V alloy. Design/methodology/approach First, the ECAJM equipment was set up, and a series of experiments for the surface machining of Ti-6Al-4V alloy was performed. Findings The experimental results show that the flowing abrasives of 0.05 Wt.% can effectively remove the TiO2 oxide film of Ti-6Al-4V alloy surface. In addition, the flowing abrasives produce cutting machining effect on the surface of titanium aluminum alloy, and the oxide film can be removed effectively. For the case of machining pressure of 0.4 Mpa and machining gap of 0.4 mm, the processing efficiency can be achieved up to 20 µm/s. Originality/value Under different machining pressure, the flowing abrasive with high kinetic energy impacting the Ti-6Al-4V alloy surface and the oxide film produced from the electrolytic reaction process can be removed effectively, thereby enhancing the efficiency of electrochemical machining process.

Electrochemical Micro Machining of Stainless Steel in EDTA Complex Electrolyte

2013 ◽  
Vol 446-447 ◽  
pp. 214-218 ◽  
Author(s):  
Hui Chen ◽  
Lei Shi ◽  
Zhi Yong Wang ◽  
Shui Qin Yu
Keyword(s):  
Stainless Steel ◽  
Oxide Layer ◽  
Ethylenediaminetetraacetic Acid ◽  
Electrochemical Machining ◽  
Electrolyte Composition ◽  
Machining Parameters ◽  
Micro Machining ◽  
Edta Complex ◽  
Micro Holes ◽  
The Stability

Electrochemical micro machining is a critical micro machining technology. The purpose of this paper is to study the effect of ethylenediaminetetraacetic acid (EDTA) complex electrolyte in electrochemical micro machining (ECM) of stainless steel. The micro machining of stainless steel is difficult by electrochemical machining, especially in machining deep micro holes, because of an oxide layer formed on the surface. In this paper, ECM of stainless steel in EDTA complex electrolyte was researched. The influence of electrochemical machining parameters such as pulse duration, electrolyte composition to machine stainless steel was investigated. The results showed that EDTA can enhance the stability of electrochemical machining and the electrolyte is eco-friendly.

Modeling of burr thickness in micro-end milling of Ti6Al4V

2018 ◽  
Vol 233 (4) ◽  
pp. 1087-1102 ◽  
Author(s):  
Vipindas Kizhakken ◽  
Jose Mathew
Keyword(s):  
Mathematical Model ◽  
Prediction Error ◽  
End Milling ◽  
Value Added ◽  
Material Model ◽  
Machining Process ◽  
Micro Machining ◽  
Proposed Model ◽  
Wide Range ◽  
Micro End Milling

Mechanical micro-machining of Ti6Al4V is finding great demand because of its wide range of application in various fields such as communication, optics and biomedical devices. Increasing demands on functioning and performance requires components to be free from burrs after the machining process. Presence of burrs on micro-mechanical parts or features significantly affects quality and proper assembly of the parts. Also in micro-machining, the size of burr is comparable to that of micro-features. Since the formation of burr is inevitable in any machining process, generally the deburring operation is performed to remove burrs. Burr thickness is one of the important parameters which describe the time and method necessary for the deburring operation. Burrs on micro-parts are generally characterized using scanning electron microscope, which is a time-consuming, costly and non-value-added activity. However, a proper mathematical model will help predict burr thickness easily. In this article, a mathematical model to predict burr thickness during micro-end milling of Ti6Al4V is presented. The proposed model was developed based on the principle of continuity of work at the transition from chip formation to burr formation. Ti6Al4V titanium alloy is one of the materials which generates segmented (saw-tooth) chips at low cutting speeds. Hence, initially an appropriate material constitutive model was selected based on better prediction of burr thickness. Then, to reduce the prediction error, machining temperature was evaluated for all experimental conditions and included in the model. From the initial study, it was found that Hyperbolic TANgent material model gives a better prediction compared to Johnson–Cook material model. Later, after including machining temperature into the model it was observed that the prediction error was reduced. The proposed model was validated with the experimental results.

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