scholarly journals Effects of Helical Tube Electrode Structure on Mixed Machining Product Transfer in Micro-Machining Channel during Tube Electrode High-Speed Electrochemical Discharge Machining

Micromachines ◽  
2019 ◽  
Vol 10 (10) ◽  
pp. 634 ◽  
Author(s):  
Yan Zhang ◽  
Chen Wang ◽  
Yu Wang ◽  
Lei Ji ◽  
Jian Tang ◽  
...  
Keyword(s):  
Flow Field ◽  
High Speed ◽  
High Efficiency ◽  
Helical Structure ◽  
Tool Electrode ◽  
Electrode Structure ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Tube Electrode ◽  
Processed Products

In tube electrode high-speed electrochemical discharge machining (TSECDM), mixed products are constantly produced in the narrow machining gap by simultaneous discharge erosion and electrochemical dissolution. For the high-efficiency removal of these products from the machining gap, a tool electrode with an optimized helical structure was utilized in TSECDM in this study. Firstly, the concentration distributions of the processed products in the machining gap using tube electrode tools with three typical helical structures were studied through the simulation of solid–liquid coupling; this showed that a trapezoidal helical structure benefited the reduced accumulation of products in grooves and the effective removal of products from the machining gap. Secondly, the main geometric parameters of the trapezoidal helical structure, including the helical groove depth, pitch, and tooth angle, were optimized by gap flow-field simulation to enhance the removal effect on processed products. Finally, it was verified that the trapezoidal helical electrode showed a definitive and significant advantage over the ordinary cylindrical electrode in effectively removing processed products from the machining gap by the comparison of flow-field simulations and actual machining experiments.

Investigation of Circuit Parameters in Tube Electrode High-Speed Electrochemical Discharge Machining

2020 ◽  
Author(s):  
Yan Zhang ◽  
Islam Md. Rashedul ◽  
Lei Ji ◽  
Baoyang Jiang
Keyword(s):  
High Speed ◽  
Limiting Factors ◽  
Matlab Simulation ◽  
Machining Performance ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Tube Electrode ◽  
Rlc Circuit ◽  
Micro Holes ◽  
Selection Parameters

Abstract Tube electrode high-speed electrochemical discharge machining (TSECDM) has been effectively used in the manufactures of micro holes with difficult-to-cut conductive materials in the field of aerospace industry. The design and parameters of circuit are critical for the machining performances of TSECDM. In this paper, the influences of circuit on the TSECDM performances are studied. Firstly, a relaxation type RLC generator is designed and analyzed by MATLAB simulation. Secondly, the effects of RLC circuit parameters such a resistor (R), capacitor (C) and inductor (L) on machining performances are investigated by experiments on the bulk of SS304 alloys by limiting factors changing. Finally, the analysis achievement indicated that the circuit selection parameters value R (15Ω); C (220nF); L (0.13mH) can be used to obtain a better machining performance.

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.

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.

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.

Design and Analysis of Flow Field in Electrochemical Cutting Processing by Arranged Tube Electrode

2017 ◽  
Vol 872 ◽  
pp. 67-76
Author(s):  
Jun Yao ◽  
Yu Jun Nie ◽  
Zhi Tong Chen
Keyword(s):  
Flow Field ◽  
High Efficiency ◽  
Short Circuit ◽  
Complex Structure ◽  
Electrochemical Machining ◽  
Utilization Rate ◽  
Processing Efficiency ◽  
Machine Material ◽  
Tube Electrode ◽  
The Cost

The large complex structure integral components composed of difficult-to-machine material (such as titanium alloy, high temperature alloy) are more and more widely applied in aerospace, weapon equipment and other industries. The material utilization rate and the processing efficiency of the milling process are very low, the cost is high. Micro copper tubes (diameter 2mm, inner diameter 1.6mm) are arranged to electrode with shape to be processed, which could cut these components with a high efficiency and low cost. The fabrication of electrode is simple and convenient, so the cost of electrode could be reduced too. The flow field design is an important problem to be solved. The model of flow field is established, and flow field of different cathodes are simulated．The analysis results show that the rectifying ring is favorable for the electrochemical machining. Finally, the cathode with rectifying ring is used in processing experiment, the edge of cutting zone is orderly, no spark and short circuit occurs. Straight line and circular hole is successfully processed. The feasibility of the scheme is proved.

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