scholarly journals Ultrasound-Assisted Through-Mask Electrochemical Machining of Hole Arrays in ODS Superalloy

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5780
Author(s):  
Guoqian Wang ◽  
Yan Zhang ◽  
Hansong Li ◽  
Jian Tang
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Oxide Dispersion Strengthened ◽  
Ultrasonic Cavitation ◽  
Hole Array ◽  
High Surface Quality ◽  
Micro Hole ◽  
Ultrasound Assisted ◽  
Hole Arrays ◽  
Mask Electrochemical Machining

Micro-hole arrays have found wide applications in aerospace, precision instruments, and biomedicine. Among various methods of their production, including mechanical, laser, and electrical discharge, electrochemical machining (ECM) is considered the most lucrative due to its wide processing range, high surface quality, and excellent productivity. In particular, ultrasound-assisted through-mask ECM exhibits an enhanced machining precision due to ultrasonic cavitation, which promotes the removal of the electrolytic products and bubbles. In this study, the equation of cavitation bubble oscillation was derived and numerically solved to study the influence of six different parameters on the ultrasonic cavitation and electrolysis process, and their optimal values were determined. The feasibility of the proposed ultrasound-assisted through-mask ECM technology with the optimized parameters was experimentally corroborated by the fabrication of a high-quality hole array in an oxide dispersion strengthened (ODS) MA956 superalloy.

A Preliminary Study of the Erosion Process in Micro-Machining of Glasses with a Low Pressure Slurry Jet

2008 ◽  
Vol 389-390 ◽  
pp. 375-380 ◽  
Author(s):  
Thai Nguyen ◽  
King Pang ◽  
Jun Wang
Keyword(s):  
Fluid Flow ◽  
High Surface ◽  
Low Pressure ◽  
Outer Diameter ◽  
Micro Machining ◽  
Erosion Process ◽  
Machined Surface ◽  
High Surface Quality ◽  
Accumulation Zone ◽  
Micro Hole

The erosion process in micro-machining of brittle glasses using a low pressure slurry jet is discussed. The process capability of the technique is assessed by examining the machined surface integrity in relation to fluid flow dynamics in micro-hole generations. The holes produced are characterised by a “W” shape in the cross section, while the surface morphology is distinguished by three zones associated with the fluid flow behaviour, i.e. a direct impact zone, a wavy zone and an accumulation zone. The surfaces appear to be smooth and without cracks, indicating a predominance of the ductile mode erosion process. With the increase of pressure, the erosion rates can be enhanced as a result of the expending of the accumulation zone while the outer diameter of the holes remains unchanged. This study shows that this technique can be used for micro-machining with high surface quality, and provides an essential understanding for further research in the avenue.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

The investigation on processes of forming the parts surface layer have made of non-ferrous metals and their alloys by complex methods

2020 ◽  
pp. 66-71
Author(s):  
V.E. Inozemtsev ◽  
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Electrochemical Machining ◽  
Aluminum Bronze ◽  
Workpiece Material ◽  
Surface Microrelief ◽  
Ductile Metals ◽  
High Surface Quality ◽  
Common Effect ◽  
Processing Modes

The study had provided shows the characteristics of the some surfaces obtained with the electrochemical mechanical processing and describes the common effect of processing modes and its conditions on the surface microrelief. This shaping method is taking an efficiency on finishing operations, which are required both in traditional ways of processing by subtracting the workpiece material, and in an additive technologies. One of the main advantages of an electrochemical machining is the ability at achieving high surface quality and the absence of impacts on the lower layers of the workpiece's surface. The results of surface studies are considered with an example of aluminum, bronze-graphite, iron-graphite, and recommendations are given for improving the surface quality of ductile metal based parts including the materials of the tool blade and its characteristics. The study has focused on the turning, milling and abrasive machining. The greatest relevance of the application of this processing method is associated with the impossibility of obtaining accurate geometric parameters of parts by the most widely used shaping methods at the present, especially for processing parts made of ductile metals and its alloys.

Scanning Micro-Electrochemical Machining Process for V-Shaped Grooves

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Hao Zhong ◽  
Hao Tong ◽  
Zhiqiang Wang ◽  
Yong Li ◽  
Yubin Pu
Keyword(s):  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Microfluidic Chips ◽  
Long Distance ◽  
High Surface Quality ◽  
Micro Electrical Discharge Machining ◽  
The Given

Abstract Microstructures determine flow properties of microfluidic chip. Micromold forming is an effective method to realize mass manufacturing of microfluidic chips. This requires to machine some kind of special microstructure of high surface quality on a metal/alloy workpiece. Micro V-shaped grooves are the typical microstructures of the chip micromolds used for controlling microfluid or weld packaging. In this research, a scanning micro-electrochemical machining (ECM) process of V-shaped grooves is proposed using a tool electrode fabricated by micro–electrical discharge machining (EDM) on-machine. Theoretical and experimental research was conducted for achieving the V-shaped grooves with a given angle on die steel. A long-distance V-shaped groove with the given angle of 67 deg and the depth of 125 μm was successfully machined.

Through-mask electrochemical machining of hole arrays on molybdenum sheets

2017 ◽  
Vol 93 (5-8) ◽  
pp. 2393-2401 ◽  
Author(s):  
H. S. Li ◽  
G. Q. Wang ◽  
L. W. Li ◽  
C. P. Gao ◽  
N. S. Qu ◽  
...  
Keyword(s):  
Electrochemical Machining ◽  
Hole Arrays ◽  
Mask Electrochemical Machining

Experimental Investigation of Fabrication of Double Tapered Hole Array by Using Electroforming and Mask Electrochemical Machining

2014 ◽  
Vol 941-944 ◽  
pp. 2140-2144
Author(s):  
Xiao Hui Bao ◽  
Ping Mei Ming ◽  
Zhen Bin Lv
Keyword(s):  
Electrochemical Machining ◽  
Hole Array ◽  
Substrate Thickness ◽  
Wall Angle ◽  
Metal Mask ◽  
Good Surface ◽  
Mask Electrochemical Machining ◽  
Electrochemical Fabrication ◽  
Through Hole ◽  
Tapered Hole

Basing on an inert perforated metal mask, a hybrid electrochemical fabrication combining electroforming and mask electrochemical machining was proposed to manufacture metal through-hole array with double tapered openings. The feasibility of this novel process was investigated experimentally. The effects of pattern parameters of inert metal mask, such as wall angle, α, substrate thickness, H, hole spacing, L and hole size, D, on profiles of the resulting holes were analyzed. The experimental results show that the hybrid fabrication is able to manufacture high-aspect-ratio double tapered hole array with good surface quality.

Effect of Micro-EDM on Diameter Consistency of Micro-Hole Arrays

2014 ◽  
Vol 609-610 ◽  
pp. 1489-1493
Author(s):  
Guo Zheng Zhu ◽  
Ji Cheng Bai ◽  
Yong Yi Huang
Keyword(s):  
Electrical Discharge ◽  
Average Diameter ◽  
Digital Printing ◽  
Maximum Diameter ◽  
Hole Array ◽  
Tool Electrode ◽  
Micro Edm ◽  
Micro Hole ◽  
Hole Arrays ◽  
The Relationship

The inkjet template is an important part of digital printing equipment. The diameter of hole arrays on the template determines the consistency of the ink droplet and thus affects print quality. To improve the printing performance of digital printing equipment, this study investigated the effect of micro-electrical discharge machining (micro-EDM) on the diameter consistency of micro-hole arrays on an inkjet template. Combining block electrical discharge grinding and wire electrical discharge grinding enabled the online processing of the fine tool electrode, whose diameter can be stably controlled at less than 45 μm, whose maximum diameter deviation was about 1 μm. The tool electrode can also be used to process micro-hole arrays. Subsequently, the relationship between the discharge energy of micro-EDM and the erosion material was theoretically analyzed, as was the effects of the diameter consistency of the micro-electrode itself on that of the micro-hole array processed by the micro-electrode and the relationship between processing parameters and the discharge gap between the micro-electrode and the workpiece. Experimentations were conducted on the effect of the flow rate, flush angle, and rotation speed of the electrode and the resistivity of de-ionized water to the diameter consistency of the micro-hole arrays. On the optimized parameters, a 16×16 micro-hole array with a diameter deviation of less than 2 μm was successfully processed, and the average diameter of the holes, about 44 μm, was used for the inkjet template. Beside, an electrode with a diameter of 14μm is also machined and it was used to process a 8×8 micro-hole array, whose diameter deviation is 0.9μm and average diameter is less than 20μm. Large number of experiments show that by the proposed method, one electrode can stably machined 800 holes with diameter less than 50μm, and their diameter deviation is less than 3μm. ​The digital printing equipment with these holes can meet the current demand for components with micro-hole arrays.

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