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.

scholarly journals Performance Improvement of High-speed Edm and Ecm Combined Process by Using a Helical Tube Electrode With Matched Internal and External Flushing

2021 ◽  
Author(s):  
Lei Ji ◽  
Yan Zhang ◽  
Guoqian Wang ◽  
Jie Zhang ◽  
Wentao Yang
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Machining Parameters ◽  
Tube Electrode ◽  
Helical Tube ◽  
Narrow Gaps ◽  
Helical Electrode

Abstract Micro-hole fabrication at a high speed and accuracy of machining while maintaining high surface quality is challenging. A core difficulty is the removal of the products of machining from extremely narrow gaps. To solve this problem, this study proposes an approach that combines high-speed electrical discharge machining (EDM) with electrochemical machining (ECM) by using a helical tube electrode with matched internal and external flushing. During high-speed electrical discharge drilling, matching the internal flushing with the clockwise rotation of the helical electrode can help remove debris from the bottom of the blind hole. During ECM, matching the external flushing with the anticlockwise rotation of the helical electrode can improve the flow of electrolyte in the gap. First, the flow field was simulated to show that matching the internal and external flushing of the helical electrode can enhance the flow of the medium and reduce particle concentration in extremely narrow gaps. Second, a series of experiments were conducted to verify that the taper of the hole and the surface quality of its wall can be improved by using the helical tube electrode. Finally, an experiment was carried out to optimize the machining parameters, and yielded a minimum taper of 0.008 at a speed of rotation of 460 rpm, and pressures of internal and external flushing of 9 MPa and 4 MPa, respectively.

Precise-Micro PECM System and its Applications Combining Synchronizing Ultrasonical Vibration

2011 ◽  
Vol 295-297 ◽  
pp. 834-839 ◽  
Author(s):  
Yong Wei Zhu ◽  
Xing Lei Miao ◽  
Chao Feng Zhang
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Electrical Discharge Machining ◽  
New Technology ◽  
Electrochemical Machining ◽  
Electrical Circuit ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Micro Machining ◽  
High Productivity

The micro-PECM (Pulse Electrochemical Machining) combining synchronous ultrasonic vibration is proposed as a new technology for to solve the difficulty machining problems of conductive hard and tough materials. The feasibility of micro-PECM combining synchronous ultrasonic vibration is studied. The synchronous way is analyzed; the synchronous electrical circuit is designed and made. The synchronous electrochemical micro-machining system combining ultrasonical vibration are built and improved，which machining parameters can be adjusted in a wide ranges, and the synchronous target of the ultrasonical vibration with the voltage of micro-PECM can be realized. The micro-machining electrodes are manufactured in different sections and sizes by combined electrical discharge machining. The mechanism tests of micro-PECM are carried, which kentaniums （YBD151、YG8）and stainless steel are machined and the results are analyzed and discussed. Contrast with the single micro-USM, the micro-PECM combining ultrasonic vibration has high productivity, good machining accuracy and surface quality; furthermore, its cathode wastage is low. The micro-PECM combining synchronous ultrasonic vibration has the best machining precision and surface quality.

scholarly journals Study of ultrasonic vibration–assisted thread turning of Inconel 718 superalloy

2019 ◽  
Vol 11 (10) ◽  
pp. 168781401988377
Author(s):  
Yu He ◽  
Zhongming Zhou ◽  
Ping Zou ◽  
Xiaogang Gao ◽  
Kornel F Ehmann
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Inconel 718 ◽  
Gas Turbines ◽  
Tool Path ◽  
Machining Parameters ◽  
Thread Cutting ◽  
Workpiece Surface ◽  
Inconel 718 Superalloy ◽  
The Relationship

With excellent properties, high-temperature superalloys have become the main application materials for aircraft engines, gas turbines, and many other devices. However, superalloys are typically difficult to machine, especially for the thread cutting. In this article, an ultrasonic vibration–assisted turning system is proposed for thread cutting operations in superalloys. A theoretical analysis of ultrasonic vibration–assisted thread cutting is carried out. An ultrasonic vibration–assisted system was integrated into a standard lathe to demonstrate thread turning in Inconel 718 superalloy. The influence of ultrasonic vibration–assisted machining on workpiece surface quality, chip shape, and tool wear was analyzed. The relationship between machining parameters and ultrasonic vibration–assisted processing performance was also explored. By analyzing the motion relationship between tool path and workpiece surface, the reasons for improved workpiece surface quality by ultrasonic vibration–assisted machining were explained.

Prediction of Surface Roughness in Compressed Air Jet Assisted High Speed End Milling of Silicon Using Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 41-45
Author(s):  
A.K.M. Nurul Amin ◽  
M.A. Mahmud ◽  
M.D. Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
Silicon Wafers ◽  
Compressed Air ◽  
Machining Parameters ◽  
High Quality ◽  
Ductile Mode

The majority of semiconductor devices are made up of silicon wafers. Manufacturing of high-quality silicon wafers includes numerous machining processes, including end milling. In order to end mill silicon to a nano-meteric surface finish, it is crucial to determine the effect of machining parameters, which influence the machining transition from brittle to ductile mode. Thus, this paper presents a novel experimental technique to study the effects of machining parameters in high speed end milling of silicon. The application of compressed air, in order to blow away the chips formed, is also investigated. The machining parameters’ ranges which facilitate the transition from brittle to ductile mode cutting as well as enable the attainment of high quality surface finish and integrity are identified. Mathematical model of the response parameter, the average surface roughness (Ra) is subsequently developed using RSM in terms of the machining parameters. The model was determined, by Analysis of Variance (ANOVA), to have a confidence level of 95%. The experimental results show that the developed mathematical model can effectively describe the performance indicators within the controlled limits of the factors that are being considered.

Investigation on Chip Morphology and Surface Quality in High-Speed Ball-End Milling of Inconel 718

2010 ◽  
Vol 443 ◽  
pp. 353-358 ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
Surface Quality ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Chip Morphology ◽  
Helix Angle ◽  
Processing Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Ball End Milling

The ball end milling process, commonly used for generating complex shapes, involves continuous variation in the uncut chip dimensions, which depends on the cutter geometry and the machining parameters. The proposed analytical model evaluates the undeformed and the deformed chip dimensions including chip length, width and thickness. The undeformed and deformed chip dimensions, is a function of cutter rotation angle, instantaneous cutter radius, helix angle, and other processing parameters. The surface quality, in the form of surface roughness, during high-speed ball end milling of Inconel 718 is also analysed in this paper.

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.

Study on Surface Quality of Al/SiCp Composites with Ultrasonic Vibration High Speed Milling

2010 ◽  
Vol 42 ◽  
pp. 363-366 ◽  
Author(s):  
Dao Hui Xiang ◽  
Xin Tao Zhi ◽  
Guang Xi Yue ◽  
Guo Fu Gao ◽  
Bo Zhao
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Formation Mechanism ◽  
High Speed ◽  
High Hardness ◽  
Machined Surface ◽  
Sic Particles ◽  
High Efficient ◽  
Ultrasonic Milling ◽  
Vibration Milling

Al/SiCp composites with excellent physical and mechanical properties are applied widely in the aerospace, automotive, national defense, electronics and other fields. High content and high hardness SiC particles lead to poor machinability and that further application is restricted. Surface microstructure and surface formation mechanism of Al/SiCp composites were studied under condition of ultrasonic vibration milling and conventional milling. The experimental results show that machined surface had the same defects, but SiC particles were mainly direct sheared in ultrasonic milling different from the conventional milling, the roughness (Ra) of the surface generated in the ultrasonic vibration milling was smaller. At last, the formation mechanism of surface topography in the ultrasonic milling was analyzed. The research indicated that ultrasonic milling could obtain better surface quality than conventional milling and with high efficient.

Research on NC Electrochemical Mechanical Drilling

2012 ◽  
Vol 271-272 ◽  
pp. 476-482
Author(s):  
Wei Min Gan ◽  
Bo Xu ◽  
Zhi Fang Zhao
Keyword(s):  
Stainless Steel ◽  
Electrochemical Machining ◽  
304 Stainless Steel ◽  
High Temperature Alloy ◽  
Mechanical Grinding ◽  
High Quality ◽  
Taper Angle ◽  
Composite Cathodes ◽  
High Efficient ◽  
Drilling Method

NC electrochemical mechanical drilling was based on NC, Electrochemical machining and mechanical grinding. It drilled with different diameter composite cathodes. This kind of drilling method took the advantages of electrochemical mechanical, so it was not restricted by parts’ strength, hardness and stiffness. The cover of cathode ensured the drilling precision. So this technology should be studied. This paper took 304 stainless steel and high temperature alloy GH710 to do study, at last the reasonable and high efficient process parameters were found in the experiment. The high quality holes of better roundness and small taper angle were drilled. The results showed that the study of NC electrochemical mechanical drilling difficult-to-machine materials was very meaningful.

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