Influence of electrolytes on surface texture characteristics generated by electrochemical micromachining

2018 ◽  
Vol 1 (2) ◽  
pp. 124-133 ◽  
Author(s):  
Sandip Kunar ◽  
S. Mahata ◽  
B. Bhattacharyya
Keyword(s):  
Flow Rate ◽  
Surface Engineering ◽  
Pulse Frequency ◽  
Electrochemical Micromachining ◽  
Duty Ratio ◽  
Machining Time ◽  
Novel Approach ◽  
Best Parameter ◽  
Work Samples ◽  
Set Up

Generation of microsurface texture is an important technology for surface engineering that can produce a significant improvement of engineering components in aspects to wear resistance, friction coefficient, load capacities, part lubrication, etc. This research proposes a novel approach of maskless electrochemical micromachining (EMM), which is anodic dissolution based on electrochemical reaction. One reused textured cathode tool with patterned SU-8 2150 mask can fabricate many work samples economically with less time. Maskless EMM set-up with developed EMM cell and vertical crossflow electrolyte supply system is used to generate micro circular patterns on stainless steel (SUS 304) using three different types of electrolytes such as NaCl, NaNO3 and NaCl + NaNO3. The influences of major process parameters such as interelectrode gap (IEG), flow rate, machining time and electrolyte concentration on mean radial overcut and mean machining depth have been investigated using these electrolytes. Out of these three electrolytes, only NaCl + NaNO3 of 20 g l−1 is selected as the best electrolyte with other best parameter settings such as applied voltage of 12 V, duty ratio of 30%, pulse frequency of 5 kHz, flow rate of 3.12 m3 hr−1, IEG of 50 µm and machining time of 3 minutes for generating good textured characteristics with overcut of 27.581 µm and depth of 15.1 µm. Analyses have also been done to investigate the textured characteristics using these electrolytes for acquiring the best parametric combination with suitable electrolyte.

scholarly journals Fabrication of various micropatterns by maskless micro-electrochemical texturing

2019 ◽  
Vol 6 ◽  
pp. 6 ◽  
Author(s):  
Sandip Kunar ◽  
Bijoy Bhattacharyya
Keyword(s):  
Flow Rate ◽  
Cross Flow ◽  
Pulse Frequency ◽  
Electrochemical Micromachining ◽  
Duty Ratio ◽  
Machining Accuracy ◽  
Machining Time ◽  
Interelectrode Gap ◽  
Set Up ◽  
Cell Electrode

In this paper, an innovative and alternative concept of maskless micro-electrochemical texturing is exploited for the fabrication of simple and complex micropatterns. In this process, the tool is masked incorporated with the textured patterns and the workpiece has no mask. This research study concentrates on generation of simple micropattern, i.e. linear micropattern, and complex micropattern, i.e. cascade micropattern using maskless micro-electrochemical texturing method without repeated use of photolithography process. A single masked patterned tool with SU-8 2150 mask can produce many high-quality simple and complex micropatterns economically using this method. A well-planned experimental set-up consisting of electrochemical micromachining (EMM) cell, electrode fixtures, electrical connections and constricted vertical cross-flow electrolyte system has been designed and developed indigenously for carrying out the experiments. Influences of major influencing parameters, i.e. machining voltage, interelectrode gap, flow rate and machining time, are investigated on width overcut and machining depth of micropatterns. For higher machining accuracy, controlled depth and lower standard deviations, machining with lower machining time, lower voltage, lower interelectrode gap and higher flow rate is recommended. From the detailed experimental investigation, the best parametric combination are voltage of 8 V, duty ratio of 30%, pulse frequency of 15 kHz, electrolyte of NaCl (0.34 M) + NaNO3 (0.23 M), flow rate of 5.35 m3/h, interelectrode gap of 50 µm and machining time of 40 s.

scholarly journals Fabrication of array of micro circular impressions using different electrolytes by maskless electrochemical micromachining

2020 ◽  
Vol 7 ◽  
pp. 15 ◽  
Author(s):  
S. Kunar ◽  
E. Rajkeerthi ◽  
K. Mandal ◽  
B. Bhattacharyya
Keyword(s):  
Experimental Investigation ◽  
Cross Flow ◽  
Surface Characteristics ◽  
Pulse Frequency ◽  
Electrochemical Micromachining ◽  
Duty Ratio ◽  
Mixed Electrolyte ◽  
Radial Overcut ◽  
Cell Electrode ◽  
Electrical Connections

Maskless electrochemical micromachining (EMM) is a prominent technique for producing the array of micro circular impressions. A method for producing the array of micro circular impressions on stainless steel workpiece applying maskless electrochemical micromachining process is presented. The experimental setup consists of maskless EMM cell, electrode holding devices, electrical connections of electrodes and constricted vertical cross flow electrolyte system to carry out the experimental investigation. One non-conductive masked patterned tool can produce more than twenty six textured samples with high quality. A mathematical model is developed to estimate theoretically the radial overcut and machining depth of the generated array of micro circular impressions by this process and corroborate the experimental results. This study provides an elementary perceptive about maskless EMM process based on the effects of EMM process variables i.e. pulse frequency and duty ratio on surface characteristics including overcut and machining depth for NaCl, NaNO3 and NaNO3 + NaCl electrolytes. From the experimental investigation, it is observed that the combined effect of lower duty ratio and higher frequency generates the best array of micro circular impressions using the mixed electrolyte of NaNO3 + NaCl with mean radial overcut of 23.31 µm and mean machining depth of 14.1 µm.

FABRICATIONS OF MICRO TOOLS AND MICRO PATTERNS BY ELECTROCHEMICAL MICROMACHINING AND SOME INVESTIGATION INTO OVERPOTENTIAL

2013 ◽  
Vol 12 (02) ◽  
pp. 85-106 ◽  
Author(s):  
V. K. JAIN ◽  
A. S. CHAUHAN ◽  
ANURAG THAKUR ◽  
AJAY SIDPARA
Keyword(s):  
Duty Cycle ◽  
Electrolyte Concentration ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Duty Ratio ◽  
Machining Time ◽  
Interelectrode Gap ◽  
Advanced Machining ◽  
Micro Tools ◽  
Micro Patterns

Electrochemical micromachining (ECMM) is a well-known advanced machining process for fabrication of micro components such as tools, nozzles, mixers, etc. on electrically conductive workpieces. In the present work, experiments are conducted for fabrication of micro tools and micro patterns on the in-house developed and fabricated electrochemical micromachining setup. Effect of various process parameters such as voltage, interelectrode gap, machining time, duty cycle, and electrolyte concentration are studied on micro tools and over potential (in case of fabrication of micro patterns). It is observed that the average change in diameter of the micro tool after the ECMM process increases almost linearly with increase in voltage and time, and increases quadratically with increase in pulse duty ratio and electrolyte concentration. Overpotential increases with increase in applied voltage, interelectrode gap, and duty cycle. Further, overpotential initially decreases quadratically with increase in electrolyte concentration and then increases.

Process Parameter Optimization and Experimental Study of Micro-Holes in Electrochemical Micromachining Using Pulse Current

2010 ◽  
Vol 135 ◽  
pp. 293-297 ◽  
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu
Keyword(s):  
Electrolyte Concentration ◽  
Pulse Frequency ◽  
Electrochemical Process ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Ultrasonic Frequency ◽  
Voltage Range ◽  
Micro Holes ◽  
Set Up ◽  
Pulse On Time

Electrochemical micro-machining (EMM) has become one of the main machining methods for production of miniaturized parts and components. Utilizing a developed EMM set-up, sets of experiments have been carried out to investigate the influences of some of the predominant electrochemical process parameters such as pulse frequency, feed rate of tool, machining voltage and ultrasonic frequency on the machining accuracy of micro-holes. According to the present investigation, the most effective zone of pulse on time and ultrasonic frequency can be considered as 15-50μs and 26KHZ, respectively, which can gives a desirable machining accuracy for micro-holes. A machining voltage range of 6-10V can be commended to obtain high machining accuracy. From the micrographs of the machined micro-holes, it may be observed that a lower value of electrolyte concentration with moderate machining voltage and moderate value of pulse on time will produce more accurate shape of micro-holes.

On the Influence of the Slot Orifice in Diesel Common Rail Nozzle

2018 ◽  
Vol 11 (1) ◽  
pp. 55-69 ◽  
Author(s):  
Giancarlo Chiatti ◽  
Ornella Chiavola ◽  
Fulvio Palmieri ◽  
Roberto Pompei
Keyword(s):  
Cross Section ◽  
Flow Rate ◽  
Experimental Analysis ◽  
Common Rail ◽  
Spray Angle ◽  
The Novel ◽  
Hydraulic Behavior ◽  
Reference Information ◽  
Light Duty ◽  
Set Up

Background:The paper deals with a diesel common rail nozzle in which a novel orifice layout is implemented.Objective:Its influence on the nozzle mechanical-hydraulic behavior and on the spray shape transient development is experimentally investigated.Methods:In the research, a solenoid injector for light duty diesel engines is equipped with the novel nozzle prototype and tested. The prototype layout is described, pointing out the features of the nozzle orifices, in which a Slot cross-section is adopted; the investigation is accomplished extending the hydraulic tests and the spray visualizations to a reference nozzle with standard holes. The influence of the hole layout on the mechanical-hydraulic behavior of the nozzle is assessed by experimental analysis based on the rate of injection measurement, in comparison with the reference nozzle. Once the hydraulic behavior of the novel nozzle has been characterized in terms of mass flow rate, the slot influence on the spray shape is assessed analyzing the macroscopic features such as the penetration distance and the spray angle, in non evaporative conditions. The study is carried out under transient injection conditions, for different injection pressures, up to 1400 bar.Results:The results on spray characteristics also provide reference information to set up spray models suited to take the Slot orifice into account.

scholarly journals Using uniform design and regression methodology of turning parameters study of nickel alloy

2021 ◽  
Author(s):  
Shao-Hsien Chen ◽  
Chih-Hung Hsu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Nickel Alloy ◽  
Design Methodology ◽  
Cutting Tool ◽  
Uniform Design ◽  
Machining Time ◽  
Variable Parameters ◽  
Cutting Test ◽  
Set Up

AbstractThe nickel alloy has good mechanical strength and corrosion resistance at high temperature; it is extensively used in aerospace and biomedical and energy industries, as well as alloy designs of different chemical compositions to achieve different mechanical properties. However, for high mechanical strength, low thermal conductivity, and surface hardening property, the nickel alloy has worse cutting tool life and machining efficiency than general materials. Therefore, how to select the optimum machining parameters will influence the workpiece quality, cost, and machining time. This research will be using a new experimental design methodology to the cutting parameter planning for nickel-based alloy cutting test, and used the uniform design methodology to cutting test to reduce the number of experiments. Three independent variable parameters are set up, including cutting speed, feed rate, and cutting depth, and four dependent variable parameters are set up, including cutting tool wear, surface roughness, machining time, and cutting force. A nickel alloy turning parameter model is built by using regression analysis to further predict the I/O relationship among various combinations of variables. The errors between actual values and prediction values are validated. When the cutting tool wear (VB) is 2.72~6.18%, the surface roughness (Ra) is 4.10~7.72%, the machining time (T) is 3.75~8.82%, and the cutting force (N) is 1.54~7.42%; the errors of various dependent variables are approximately less than 10%, so a high precision estimation model is obtained through a few experiments of uniform design method.

Degradation of Organophosphorus Pesticide in a Packed-Bed Plasma Reactor: Effects of Operating Parameters and Kinetics Study

2013 ◽  
Vol 781-784 ◽  
pp. 1637-1645 ◽  
Author(s):  
Ting Jun Ma ◽  
Yi Qing Xu
Keyword(s):  
Removal Efficiency ◽  
Flow Rate ◽  
Gas Flow ◽  
Plasma Reactor ◽  
Organophosphorus Pesticide ◽  
Packed Bed ◽  
Pulse Frequency ◽  
Gas Flow Rate ◽  
Peak Voltage ◽  
Initial Concentration

The degradation effectiveness and reaction kinetics of representative organophosphorus (OP) pesticide in a packed-bed plasma reactor have been studied. Important parameters, including peak voltage, pulse frequency, gas-flow rate, initial concentration, diameter of catalyst particles, and thickness of catalyst bed which influences the removal efficiency, were investigated. Experimental results indicated that rogor removal efficiency as high as 80% can be achieved at 35 kV with the gas flow rate of 800 mL/min and initial concentration of 11.2 mg/m3.The removal efficiency increased with the increase of pulsed high voltage, and pulse frequency, the decrease of the diameter of catalyst particles and the thickness of catalyst bed. Finally, a model was established to predict the degradation of the rogor, which generally can simulate the experimental measurements to some degree.

Detektion von Bauteilfehlern aus Maschinendaten/Detection of workpiece flaws out of machine tool data – possibilities and limits

2019 ◽  
Vol 109 (11-12) ◽  
pp. 828-832
Author(s):  
M. Weigold ◽  
A. Fertig ◽  
C. Bauerdick
Keyword(s):  
Quality Assurance ◽  
Machine Tool ◽  
Machine Tools ◽  
Machining Time ◽  
Parallel Detection ◽  
High Data ◽  
Novel Approach ◽  
Data Rates ◽  
High Data Rates

Durch zunehmende Vernetzung und Digitalisierung von Werkzeugmaschinen und Automatisierungskomponenten ergibt sich die Möglichkeit, Signale mit hohen Datenraten und großer Vielfalt aufzuzeichnen. Der vorliegende Beitrag beschreibt erste Untersuchungen zur Realisierbarkeit einer prozessparallelen Detektion von Bauteilfehlern auf Basis interner Werkzeugmaschinendaten. Dabei werden Potenziale und Grenzen für diesen neuartigen Ansatz zur hauptzeitparallelen Qualitätssicherung aufgezeigt.   The increasing networking and digitization of machine tools and automation components provides the opportunity to record signals with high data rates and great diversity. This paper describes first investigations on the feasibility of a process-parallel detection of component defects on the basis of internal machine tool data. Potentials and limits for this novel approach to quality assurance parallel to machining time are presented.

Influence of High Duty Ratio and Frequency in WECM Employing In Situ Fabricated Wire Electrode

2017 ◽  
Vol 5 (4) ◽  
Author(s):  
S. Debnath ◽  
J. Kundu ◽  
B. Bhattacharyya
Keyword(s):  
Mathematical Modeling ◽  
Electrochemical Machining ◽  
Burr Formation ◽  
Duty Ratio ◽  
Minimum Width ◽  
Applied Frequency ◽  
Early Adoption ◽  
Novel Approach ◽  
Microfabrication Techniques

To adapt with today's rapidly changing world, fabrication of intricate microparts is becoming an urgent need. Manufacturing of these microparts with stringent requirements necessitates the early adoption of different microfabrication techniques. Wire electrochemical machining (WECM) is such a process which removes excess metal by dissolving it electrochemically. This process can easily generate features downscaled to micron ranges and offers several advantages like the requirement of very simple setup, fabrication of accurate complex microfeatures without undergoing any thermal stress, burr formation, and tool wear, which make it superior from other existing micromachining processes. However, this process is new, and little is known about its applicability and feasibility. Hence, the present work is directed towards developing suitable WECM setup to fabricate microfeatures by introducing proper means for enhancing the mass transport phenomenon. The tungsten tool wire for machining has been in situ etched to a diameter of 23.43 μm by a novel approach for retaining its regular cylindrical form and has been implemented during machining. Moreover, the influences of high duty ratio and applied frequency have been investigated on the corresponding width of the fabricated microslits and the experimental results have been represented graphically where the minimum width of the microslit is obtained as 44.85 μm. Furthermore, mathematical modeling has been developed to correlate duty ratio and applied frequency with generated slit width. Additionally, the mathematical modeling has been validated with practical results and complex stepped type microfeatures have been generated to establish process suitability.

scholarly journals Optimal Falling Track Design for Twice detonating Fuze of Double event Fuel air Explosive with High Speed

2020 ◽  
Vol 70 (4) ◽  
pp. 366-373
Author(s):  
Congliang Ye ◽  
Qi Zhang
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Single Point ◽  
Design System ◽  
Motion Trajectory ◽  
Novel Approach ◽  
Scale Experiment ◽  
Set Up ◽  
Point Center ◽  
Double Event

To prevent the initiation failure caused by the uncontrolled fuze and improve the weapon reliability in the high-speed double-event fuel-air explosive (DEFAE) application, it is necessary to study the TDF motion trajectory and set up a twice-detonating fuze (TDF) design system. Hence, a novel approach of realising the fixed single-point center initiation by TDF within the fuel air cloud is proposed. Accordingly, a computational model for the TDF motion state with the nonlinear mechanics analysis is built due to the expensive and difficult full-scale experiment. Moreover, the TDF guidance design system is programmed using MATLAB with the equations of mechanical equilibrium. In addition, by this system, influences of various input parameters on the TDF motion trajectory are studied in detail singly. Conclusively, the result of a certain TDF example indicates that this paper provides an economical idea for the TDF design, and the developed graphical user interface of high-efficiency for the weapon designers to facilitate the high-speed DEFAE missile development.

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