scholarly journals Fabrication of Microgrooves by Synchronous Hybrid Laser and Shaped Tube Electrochemical Milling

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7714
Author(s):  
Yong Yang ◽  
Yufeng Wang ◽  
Yujie Gui ◽  
Wenwu Zhang
Keyword(s):  
Surface Roughness ◽  
Laser Power ◽  
Electrochemical Machining ◽  
Bottom Surface ◽  
Machining Accuracy ◽  
Machining Efficiency ◽  
Layer By Layer ◽  
Shaped Tube ◽  
Side Gap ◽  
Electrochemical Milling

The fabrication of deep microgrooves has become an issue that needs to be addressed with the introduction of difficult-to-cut materials and ever-increasing stringent quality requirements. However, both laser machining and electrochemical machining could not fulfill the requirements of high machining efficiency and precision with good surface quality. In this paper, laser and shaped tube electrochemical milling (Laser-STEM) were initially employed to fabricate microgrooves. The mechanisms of the Laser-STEM process were studied theoretically and experimentally. With the developed experimental setup, the influences of laser power and voltage on the width, depth and bottom surface roughness of the fabricated microgrooves were studied. Results have shown a laser power of less than 6 W could enhance the electrochemical machining rate without forming a deep kerf at the bottom during Laser-STEM. The machining accuracy or localization of electrochemicals could be improved with laser assistance, whilst the laser with a high-power density would deteriorate the surface roughness of the bottom machining area. Experimental results have proved that both the machining efficiency and the machining precision can be enhanced by synchronous laser-assisted STEM, compared with that of pure electrochemical milling. The machining side gap was decreased by 62.5% while using a laser power of 6 W in Laser-STEM. The laser-assistance effects were beneficial to reduce the surface roughness of the microgrooves machined by Laser-STEM, with the proper voltage. A laser power of 3 W was preferred to obtain the smallest surface roughness value. Additionally, the machining efficiency of layer-by-layer Laser-STEM can be improved utilizing a constant layer thickness (CLT) mode, while fabricating microgrooves with a high aspect ratio. Finally, microgrooves with a width of 1.79 mm, a depth of 6.49 mm and a surface roughness of 2.5 μm were successfully fabricated.

Influence of different featured tools on machining accuracy in electrochemical milling

2019 ◽  
pp. 095440541989279
Author(s):  
Koushik Mishra ◽  
Biplab Ranjan Sarkar ◽  
B Bhattacharyya
Keyword(s):  
Tool Path ◽  
Removal Rate ◽  
Research Work ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Layer By Layer ◽  
Mixed Electrolyte ◽  
The Impact ◽  
Tool Rotation ◽  
Electrochemical Milling

Drawbacks of electrochemical machining can be conquered to a large extent with the introduction of electrochemical milling technique. In this method, a simple shaped tool follows a predetermined tool path and material gets removed atom-by-atom from anode workpiece by electrochemical reactions through layer-by-layer approach. Keeping in mind the rising trend of electrochemical milling technique, this research work focuses to investigate the impact of major process parameters of electrochemical milling, for example, feed rate and milling layer depth on foremost responses like material removal rate and width overcut during electrochemical milling of Nimonic-263 alloy. In this research work, three different types of featured tools have been utilized and for each tool, ANSYS simulation has been carried out for analysing their impact on machining accuracy. Furthermore, these obtained simulated results have been confirmed by experimentation. Finally, an attempt has been made to produce more accurate ‘L’-shaped features on Nimonic-263 alloy with the aid of tool rotation and inner-spraying featured tools. This study confirms that mixed electrolyte, that is, NaCl(1M) + NaNO3(1M), tool rotation with internal flushing, number of outlets and the structure of the end face of the tool generate excellent machining accuracy with super finished surface with Ra value in the order of 0.07–0.08 µm during electrochemical milling of Nimonic-263 alloy.

Study on the Shaping Law of Precision Numerical Controlled Electrochemical Contour Evolution Machining

2008 ◽  
Vol 375-376 ◽  
pp. 72-76 ◽  
Author(s):  
Min Kang ◽  
Jia Wen Xu
Keyword(s):  
Differential Equations ◽  
Process Parameters ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Planar Surface ◽  
Important Development ◽  
Contour Evolution ◽  
Change Trend ◽  
Side Gap

Numerical Controlled Electrochemical Contour Evolution Machining (NC-ECCEM) is one of the most important development in Electrochemical Machining (ECM). In order to improve the machining accuracy of NC-ECCEM technology, the research works on precision NC-ECCEM technology are needed, and especially the study on its shaping law is significant for improving the machining accuracy of workpiece profile. In this paper, the shaping law of machining the planar surface by use of a kind of inner-spraying cathode with rectangle section was studied. First, the basic differential equations of shaping law in the case of cathode movement were established. Then, considering the structure of the cathode, the methods for calculating the side gap in machining the planar surface was given. Finally, the experiments of machining the planar surface were carried out. Experiments show that the calculated side gaps are bigger than the actual values, but the change trend of calculated side gaps with machining process parameters is coincident with the actual side gap change trend.

Grinding Technology of Cylindrical Surface with Protrusion

2016 ◽  
Vol 1136 ◽  
pp. 54-59
Author(s):  
Kazuya Kato ◽  
Yukio Maeda ◽  
Hideaki Tanaka
Keyword(s):  
Surface Roughness ◽  
Cylindrical Surface ◽  
Consumer Electronics ◽  
Grinding Wheel ◽  
Machining Accuracy ◽  
Grinding Process ◽  
Machining Efficiency ◽  
Highly Efficient ◽  
Cylindrical Parts ◽  
Uneven Wear

Cylindrical parts with a protrusion are expected to be used in the components of consumer electronics and automotive products. The machining efficiency of these parts is very low, making them difficult to be mass-produced. The aim of our present work is to develop a highly accurate and highly efficient grinding process for a cylindrical surface with a protrusion. This paper describes the results of experiments using a straight cup-shaped grinding wheel. The following conclusions can be drawn. (1) To prevent uneven wear of the grinding wheel, an oscillation operation is necessary during the grinding process. (2) By employing the straight cup-shaped grinding wheel, the grinding process is realized with the aim of achieving the following: high machining accuracy, roundness below 3 μm, straightness below 2 μm, and surface roughness below 2 μmRzjis.

scholarly journals Investigation of Laser Polishing of Four Selective Laser Melting Alloy Samples

2020 ◽  
Vol 10 (3) ◽  
pp. 760
Author(s):  
Dongqi Zhang ◽  
Jie Yu ◽  
Hui Li ◽  
Xin Zhou ◽  
Changhui Song ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Laser Power ◽  
Layer By Layer ◽  
Metal Powders ◽  
Laser Melting ◽  
Laser Polishing

Selective laser melting (SLM) is a layer by layer process of melting and solidifying of metal powders. The surface quality of the previous layer directly affects the uniformity of the next layer. If the surface roughness value of the previous layer is large, there is the possibility of not being able to complete the layering process such that the entire process has to be abandoned. At least, it may result in long term durability problem and the inhomogeneity, may even make the processed structure not be able to be predicted. In the present study, the ability of a fiber laser to in-situ polish the rough surfaces of four typical additive-manufactured alloys, namely, Ti6Al4V, AlSi10Mg, 316L and IN718 was demonstrated. The results revealed that the surface roughness of the as-received alloys could be reduced to about 3 μm through the application of the laser-polishing process, and the initial surfaces had roughness values of 8.80–16.64 μm. Meanwhile, for a given energy density, a higher laser power produced a laser-polishing effect that was often more obvious, with the surface roughness decreasing with an increase in the laser power. Further, the polishing strategy will be optimized by simulation in our following study.

Analysis of Reversible Fine Machining Sequence Effect on Surface Integrity

2006 ◽  
Vol 315-316 ◽  
pp. 391-395
Author(s):  
Wen Ge Wu ◽  
Si Qin Pang ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Machining Process ◽  
Processing Route ◽  
Machining Accuracy ◽  
Machining Efficiency ◽  
Micro Hardness ◽  
Rough Machining ◽  
Machined Surface

Reversible cutting method is a new research thesis proposed to shorten processing route, decrease tool number and handling time, increase machining efficiency. The aim of the presented work was to analysis the effects of reversible fine machining sequence on surface integrity in machined layer. Nonlinear hardening during reverse loading and the change of the Bauschinger effect factor with plastic strain were properly taken into account. In experiments, the residual stresses have been measured using the X-ray diffraction technique (at the surface of the workpiece and in depth). Moreover, micro-hardness and surface roughness of machined surface are presented. Experimental data for the range of cutting parameters tested showed that the reversible fine machining produce the tensile residual stresses at the surface, which are critical in the performance of the machined components. The experimental results of micro-hardness of reversible fine machining technique are smaller than that of general fine machining show that decreased plastic deformation of the surface layer and work-hardening. Surface roughness of machined surface with reversible finishing is discussed. Research results indicted that it can be adopted such planning which rough machining during advance stroke and fine machining or semi-finishing during return stroke in machining process. In this way, it has such advantages that increase machining efficiency and machining accuracy, decrease bending deformation.

Electrochemical Machining of Micro Slots Using Shaped Electrode

2012 ◽  
Vol 497 ◽  
pp. 315-319 ◽  
Author(s):  
Xiao Long He ◽  
Yu Kui Wang ◽  
Zhao Qi Zeng ◽  
Zhen Long Wang ◽  
Wan Sheng Zhao
Keyword(s):  
Electrical Discharge ◽  
Electrochemical Machining ◽  
Machining Efficiency ◽  
Flow State ◽  
Cylindrical Electrode ◽  
Shape Precision ◽  
Machining Speed ◽  
Side Gap

In this paper electrochemical machining of micro slots using a shaped electrode instead of the traditional cylindrical electrode is presented. By applying shaped electrode the flow state of processing can be improved. An electrochemical machining (ECM system for meeting the requirements of the ECM process was established and a shaped electrode was fabricated by BEDG (Block Electrical Discharge Grinding). A set of experiments were carried out to investigate the influence of shaped electrode on machining efficiency and shape precision. The results show that the side gap and frontal gap of the micro slots can be reduced and machining speed will be improved when the shaped electrode was used compare with cylindrical electrode.

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 Modeling the Layer-by-Layer Growth of HKUST-1 Metal-Organic Framework Thin Films

Nanomaterials ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1631
Author(s):  
Qiang Zhang ◽  
Yohanes Pramudya ◽  
Wolfgang Wenzel ◽  
Christof Wöll
Keyword(s):  
Thin Films ◽  
Surface Roughness ◽  
Deposition Rate ◽  
Layer Growth ◽  
Coarse Grained ◽  
Structural Defects ◽  
Effect Of Temperature ◽  
Layer By Layer ◽  
Reactant Concentration ◽  
Metal Organic

Metal organic frameworks have emerged as an important new class of materials with many applications, such as sensing, gas separation, drug delivery. In many cases, their performance is limited by structural defects, including vacancies and domain boundaries. In the case of MOF thin films, surface roughness can also have a pronounced influence on MOF-based device properties. Presently, there is little systematic knowledge about optimal growth conditions with regard to optimal morphologies for specific applications. In this work, we simulate the layer-by-layer (LbL) growth of the HKUST-1 MOF as a function of temperature and reactant concentration using a coarse-grained model that permits detailed insights into the growth mechanism. This model helps to understand the morphological features of HKUST-1 grown under different conditions and can be used to predict and optimize the temperature for the purpose of controlling the crystal quality and yield. It was found that reactant concentration affects the mass deposition rate, while its effect on the crystallinity of the generated HKUST-1 film is less pronounced. In addition, the effect of temperature on the surface roughness of the film can be divided into three regimes. Temperatures in the range from 10 to 129 °C allow better control of surface roughness and film thickness, while film growth in the range of 129 to 182 °C is characterized by a lower mass deposition rate per cycle and rougher surfaces. Finally, for T larger than 182 °C, the film grows slower, but in a smooth fashion. Furthermore, the potential effect of temperature on the crystallinity of LbL-grown HKUST-1 was quantified. To obtain high crystallinity, the operating temperature should preferably not exceed 57 °C, with an optimum around 28 °C, which agrees with experimental observations.

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