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.

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.

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 Improvement of Machining Accuracy on Quartz and Glasses by Electrochemical Discharge Machining

2014 ◽  
Vol 472 ◽  
pp. 682-687 ◽  
Author(s):  
L.W. Hourng ◽  
C.I. Lin ◽  
B.G. Lee
Keyword(s):  
Surface Roughness ◽  
Electrolyte Concentration ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Film Stability ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Working Parameters ◽  
Applied Voltage Pulse ◽  
Gaseous Bubbles

In the present study, a tungsten rod with diameter of 100μm is used as the tool to drill a quartz plate by Electrochemical Discharge Machining (ECDM). KOH solution mixed with different concentration of Ethanol is used as the electrolyte. The influences of different working parameters, such as electrolyte concentration, applied voltage, pulse frequency, and electrolyte level, on the gas film stability, gas film thickness, and machining accuracy are investigated. The experimental results show that the overcut and surface roughness is improved by the use of electrolyte with addition of 6.5wt% ethanol. The effect of gaseous bubbles is reduced during the machining, and the circulation of electrolyte is better. Compared with machining with pure KOH electrolyte, the overcut is reduced around 57% by the use of electrolyte with addition of 6.5wt% ethanol. The heat-effected zone on the machining is also largely reduced.

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.

Investigation on Electrochemical Discharge Micro-Machining of Silicon Carbide

2017 ◽  
Vol 4 (2) ◽  
pp. 29-44 ◽  
Author(s):  
B.R. Sarkar ◽  
B. Doloi ◽  
B. Bhattacharyya
Keyword(s):  
Silicon Carbide ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Micro Machining ◽  
Electrode Gap ◽  
Multi Objective ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Conducting Materials

Electrochemical discharge machining (ECDM) process has great potential to machine hard, brittle and electrically non-conducting materials in micron range. The objective of this paper is to investigate into electrochemical discharge micro-machining on electrically semi-conductor type silicon carbide (SiC) material so as to study the effects of applied voltage, electrolyte concentration and inter-electrode gap on material removal rate (MRR) and radial overcut (ROC) of micro-drilled hole. Experiments were conducted based on L9 array of Taguchi method with stainless steel µ-tool of 300µm diameter using NaOH electrolyte. An attempt has been made to find out the single as well as multi-objective optimal parametric combinations for maximum MRR and minimum ROC. The single-objective parametric combinations were selected as 45V/20wt%/20mm and 25V/20wt%/40mm for maximum MRR and minimum ROC respectively whereas multi-objective optimal parametric combinations was found as 25V/20wt%/40mm. Further mathematical models have been developed between the above machining parameters and characteristics.

Application of Electrochemical Discharge Machining to Micro-Machining of Quartz

2014 ◽  
Vol 939 ◽  
pp. 161-168 ◽  
Author(s):  
Kun Ling Wu ◽  
Hsin Min Lee ◽  
Kuan Hwa Chin
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Processing Parameters ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Process Technology ◽  
Machining Time ◽  
Optimal Processing ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge

Electrochemical discharge machining (ECDM) is the preferred non-traditional process technology in recent years, The main processing is applied to machining non-conductive hard brittle materials. This study investigated the precision and stability of quartz fabricated by ECDM and explored the optimal processing parameters including size of electrode, machining speed as well as pulse-on and pulse-off duration. Microgrooves machined under the optimal processing parameters with adjusted rotational speed and feed rate were examined to understand the effect of different ECDM parameters on machining performance. The results indicate that micro-holes of better morphology could be obtained under pulse voltage of 40 V, electrolyte concentration of 5 M, electrode size of 125 μm. Moreover, rotational speed of 1500 rpm and pulse-on/pulse-off (ms) ratio of 1:0.6 gave higher machining accuracy with smaller hole diameter and shorter machining time. Finally, microgrooves machined under the optimal processing parameters showed the best accuracy in dimension and cross-sectional morphology at rotational speed of 2500 rpm, pulse-on /pulse-off (ms) ratio of 1:1.6, and feed rate of 3000 μm/min.

Optimization of Process Parameters in Micro-Electrochemical Discharge Machining by Using Grey Relational Analysis

2020 ◽  
Vol 978 ◽  
pp. 121-132
Author(s):  
Nitesh Kumar ◽  
Harish Bishwakarma ◽  
Prasenjit Sharma ◽  
Purshottam Kumar Singh ◽  
Alok Kumar Das
Keyword(s):  
Electrolyte Concentration ◽  
Removal Rate ◽  
Machining Process ◽  
Duty Factor ◽  
Work Piece ◽  
Machining Parameters ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Hybrid Machining Process ◽  
Micro Hole

Micro-electrochemical discharge machining is hybrid machining process which is based on combined principle of electro discharge machining and electro chemical machining. It is suitable for machining of both conductive as well as non-conductive materials. In this study a micro hole drilled on Ti-6Al-4V as work piece by varying machining parameters like electrolyte concentration, voltage and duty factor at three different levels. Orthogonal array L9 considered for design and performing experiments. The Grey relation analysis (GRA) was performed to optimize the output parameters i.e. material removal rate (MRR) and hole tapper angle (HTA). The result reveals that voltage was the most significant factor for both MRR and HTA followed by electrolyte concentration and duty factor. The maximum MRR and minimum taper angle are 1.50 mg/min and 0.98 ° obtained respectively. The GRA show optimal machining parameters at electrolyte concentration 3M, voltage 40 V and duty factor 25% respectively.

Sign in / Sign up

Export Citation Format

Share Document