scholarly journals The Optimal Processing Parameters of Radial Ultrasonic Rolling Electrochemical Micromachining—RSM Approach

Micromachines ◽  
2020 ◽  
Vol 11 (11) ◽  
pp. 1002
Author(s):  
Kailei He ◽  
Xia Chen ◽  
Minghuan Wang
Keyword(s):  
High Efficiency ◽  
Electrochemical Machining ◽  
Processing Parameters ◽  
Pulse Frequency ◽  
Performance Criteria ◽  
Electrochemical Micromachining ◽  
Machining Parameters ◽  
Optimal Processing ◽  
Predicted Values ◽  
Working Parameters

Radial ultrasonic rolling electrochemical micromachining (RUR-EMM) is a new method of electrochemical machining (ECM). By feeding small and rotating electrodes aided by ultrasonic rolling, an array of pits can be manufactured, which is called microstructures. However, there still exists the problem of choosing the optimal machining parameters to realize the workpiece machining with high quality and high efficiency. In the present study, response surface methodology (RSM) was proposed to optimize the machining parameters. Firstly, the performance criteria of the RUR-EMM are measured through investigating the effect of working parameters, such as applied voltage, electrode rotation speed, pulse frequency and interelectrode gap (IEG), on material removal amount (MRA) and surface roughness (Ra). Then, the experimental results are statistically analyzed and modeled through RSM. The regression model adequacies are checked using the analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated and verified by experiment to maximize MRA and minimize Ra. The results show that each parameter has a similar and non-linear influence on the MRA and Ra. Specifically, with the increase of each parameter, MRA increases first and decreases when the parameters reach a certain value. On the contrary, Ra decreases first and then increases. Under the combined effect of these parameters, the productivity is improved. The experimental value of MRA and Ra is 0.06006 mm2 and 51.1 nm, which were 0.8% and 2.4% different from the predicted values.

Investigation on the Electrochemical Micromachining of Micro Holes with Variable Cross-Section

2014 ◽  
Vol 644-650 ◽  
pp. 4927-4931
Author(s):  
Kun Wang ◽  
Meng Gao ◽  
Qi Shen
Keyword(s):  
Cross Section ◽  
Pulse Width ◽  
Electrochemical Machining ◽  
Processing Parameters ◽  
Variable Cross Section ◽  
Electrochemical Micromachining ◽  
Variable Cross ◽  
Machining Parameters ◽  
Micro Holes ◽  
Side Gap

Based on the principle of electrochemical, the processing mechanism of electrochemical machining (ECM) micro holes is analyzed and discussed, the processing model is established and the quantitative relationship is presented between the machining side gap and the electrochemical machining parameters (pulse width and pulse period, pulse frequency, duty ratio, etc.), workpiece material parameters and the parameters of the electrolyte, the electric double layer equivalent circuit constant with mathematical expression. On the basis of the analysis of the effect of processing parameters on the electrochemical machining accuracy and stability, process out the variable cross-section micro hole at an appropriate processing parameters of variable pulse width.

Fabrication of Micro Structures by Ultra Short Voltage Pulse Electrochemical Machining

2009 ◽  
Vol 419-420 ◽  
pp. 813-816 ◽  
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Wan Sheng Zhao
Keyword(s):  
Voltage Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Stray Current ◽  
Micro Fabrication ◽  
Micro Hole ◽  
Micro Structures ◽  
Machining Localization

. The purpose of this paper is to study the application of electrochemical machining (ECM) technology for the fabrication of micro structures. The stray current corrosion, i.e. machining localization is a critical obstacle to micro fabrication for ECM. To machine micro structures by electrochemical machining ultra short voltage pulse is used. The effects of electrochemical machining parameters such as voltage, pulse duration, pulse frequency, and electrolyte composition on the machining accuracy were studied. In experiments, a micro hole was machined on stainless steel with cylindrical and square electrodes to investigate these effects.

Process Experimental Research of Micro-Hole in Electrochemical Micromachining by Nanosecond Pulse Current

2013 ◽  
Vol 764 ◽  
pp. 15-19
Author(s):  
Zhi Yong Li ◽  
Hong Li Liu ◽  
Zhi Peng Duan
Keyword(s):  
Pulse Current ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Anode Dissolution ◽  
Micro Hole ◽  
Processing Accuracy ◽  
Hole Machining

Electrochemical micro-machining (ECMM) is a method that utilizes anode dissolution principle to process shaping. In the Electrochemical machining （ECM）of micro-hole, machining precision is an important aspect to measure machining quality of micro-hole. In this paper micro-hole machining is regarded as the research object, effects of many factors such as power supply natures, electrolyte composition, pulse width and pulse frequency on machining accuracy in micro-hole ECM have been evaluated. Research shows that processing accuracy can be improved through using non-linear electrolyte in high frequency, narrow pulse electrochemical machining.

Stress-Etching Using Laser Electrochemical Micromachining with Masks

2012 ◽  
Vol 268-270 ◽  
pp. 468-472 ◽  
Author(s):  
Zhong Yang Li ◽  
Zhao Yang Zhang ◽  
Yao Min Wang ◽  
Wei Ping Mao
Keyword(s):  
Large Scale ◽  
High Efficiency ◽  
Metal Removal ◽  
Laser Energy ◽  
Electrochemical Etching ◽  
Pulsed Laser ◽  
Electrochemical Micromachining ◽  
Scale Production ◽  
Machining Parameters ◽  
Nanosecond Pulsed Laser

Metal workpiece was processed by nanosecond pulsed laser electrochemical micro-etching with masks patterns in the shape of letter "E". In the experimental system established, the effect of different laser energy on processing quality was studied in air. In the different concentrations of the electrolyte, through optimized composite machining parameters, machining results of different laser energy with the masks were analyzed and compared in Aluminum alloy and Stainless steel. There was a large of difference in machining morphology by laser electrochemical micromachining with masks in two different metal materials. The results show that laser electrochemical micro-etching with masks has high efficiency and the prospects for the large-scale production, but the etching precision should be also further improved. Moreover, the nanosecond pulsed laser thermal-stress etching, electrochemical etching and the two combined coupling etching are the main factors to achieve the metal removal.

scholarly journals Warpage Optimisation Using Recycled Polycar-bonates (PC) on Front Panel Housing

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1416
Author(s):  
Nur Aisyah Miza Ahmad Tamizi ◽  
Shayfull Zamree Abd Rahim ◽  
Abdellah El-hadj Abdellah ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Marcin Nabiałek ◽  
...  
Keyword(s):  
Simulation Analysis ◽  
Processing Parameters ◽  
Front Panel ◽  
Processing Parameter ◽  
Mechanical Recycling ◽  
Great Opportunity ◽  
Average Value ◽  
Optimal Processing ◽  
Materials Used ◽  
Optimisation Methods

Many studies have been done using recycled waste materials to minimise environmental problems. It is a great opportunity to explore mechanical recycling and the use of recycled and virgin blend as a material to produce new products with minimum defects. In this study, appropriate processing parameters were considered to mould the front panel housing part using R0% (virgin), R30% (30% virgin: 70% recycled), R40% (40% virgin: 60% recycled) and R50% (50% virgin: 50% recycled) of Polycarbonate (PC). The manufacturing ability and quality during preliminary stage can be predicted through simulation analysis using Autodesk Moldflow Insight 2012 software. The recommended processing parameters and values of warpage in x and y directions can also be obtained using this software. No value of warpage was obtained from simulation studies for x direction on the front panel housing. Therefore, this study only focused on reducing the warpage in the y direction. Response Surface Methodology (RSM) and Genetic Algorithm (GA) optimisation methods were used to find the optimal processing parameters. As the results, the optimal ratio of recycled PC material was found to be R30%, followed by R40% and R50% materials using RSM and GA methods as compared to the average value of warpage on the moulded part using R0%. The most influential processing parameter that contributed to warpage defect was packing pressure for all materials used in this study.

scholarly journals Binary Self-Assembly of Nanocolloidal Arrays using Concurrent and Sequential Spin Coating Techniques

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 274
Author(s):  
Shih-Jyun Shen ◽  
Demei Lee ◽  
Yu-Chen Wu ◽  
Shih-Jung Liu
Keyword(s):  
Silicon Substrate ◽  
Self Assembly ◽  
Spin Coating ◽  
Processing Parameters ◽  
The Self ◽  
Silicon Substrates ◽  
Processing Conditions ◽  
Polystyrene Spheres ◽  
Optimal Processing ◽  
Spin Coater

This paper reports the binary colloid assembly of nanospheres using spin coating techniques. Polystyrene spheres with sizes of 900 and 100 nm were assembled on top of silicon substrates utilizing a spin coater. Two different spin coating processes, namely concurrent and sequential coatings, were employed. For the concurrent spin coating, 900 and 100 nm colloidal nanospheres of latex were first mixed and then simultaneously spin coated onto the silicon substrate. On the other hand, the sequential coating process first created a monolayer of a 900 nm nanosphere array on the silicon substrate, followed by the spin coating of another layer of a 100 nm colloidal array on top of the 900 nm array. The influence of the processing parameters, including the type of surfactant, spin speed, and spin time, on the self-assembly of the binary colloidal array were explored. The empirical outcomes show that by employing the optimal processing conditions, binary colloidal arrays can be achieved by both the concurrent and sequential spin coating processes.

scholarly journals Selected Aspects of Electrochemical Micromachining Technology Development

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2248
Author(s):  
Sebastian Skoczypiec ◽  
Piotr Lipiec ◽  
Wojciech Bizoń ◽  
Dominik Wyszyński
Keyword(s):  
Technology Development ◽  
Electrochemical Machining ◽  
Electrochemical Micromachining ◽  
Cylindrical Electrode ◽  
Electrode Tool ◽  
Geometrical Features ◽  
Tool Trajectory ◽  
Scaling Down ◽  
Sidewall Surface ◽  
Selection Of

The paper focuses on the fundamentals of electrochemical machining technology de-elopement with special attention to applications for micromachining. In this method, a material is removed during an anodic electrochemical dissolution. The method has a number of features which make it attractive technology for shaping parts with geometrical features in range of micrometres. The paper is divided into two parts. The first one covers discussion on: general characteristics of electrochemical machining, phenomena in the gap, problems resulting from scaling down the process and electrochemical micromachining processes and variants. The second part consists of synthetic overview of the authors’ research on localization of pulse electrochemical micromachining process and case studies connected with application of this method with use of universal cylindrical electrode-tool for shaping cavities in 1.4301 stainless steel. The latter application was conducted in two following variants: electrochemical contour milling and shaping carried out with sidewall surface of rotating tool. In both cases, the obtained shape is a function of electrode tool trajectory. Selection of adequate machining strategy allows to obtain desired shape and quality.

scholarly journals Multiscale Copper-µDiamond Nanostructured Composites

2012 ◽  
Vol 730-732 ◽  
pp. 925-930
Author(s):  
Daniela Nunes ◽  
Vanessa Livramento ◽  
Horácio Fernandes ◽  
Carlos Silva ◽  
Nobumitsu Shohoji ◽  
...  
Keyword(s):  
Pure Copper ◽  
Thermal Stabilization ◽  
Hot Extrusion ◽  
Processing Parameters ◽  
High Energy ◽  
X Ray Diffraction ◽  
X Ray ◽  
Optimal Processing ◽  
Novel Approach ◽  
Transmission Electron

Nanostructured copper-diamond composites can be tailored for thermal management applications at high temperature. A novel approach based on multiscale diamond dispersions is proposed for the production of this type of materials: a Cu-nDiamond composite produced by high-energy milling is used as a nanostructured matrix for further dispersion of micrometer sized diamond. The former offers strength and microstructural thermal stability while the latter provides high thermal conductivity. A series of Cu-nDiamond mixtures have been milled to define the minimum nanodiamond fraction suitable for matrix refinement and thermal stabilization. A refined matrix with homogenously dispersed nanoparticles could be obtained with 4 at.% nanodiamond for posterior mixture with mDiamond and subsequent consolidation. In order to define optimal processing parameters, consolidation by hot extrusion has been carried out for a Cu-nDiamond composite and, in parallel, for a mixture of pure copper and mDiamond. The materials produced were characterized by X-ray diffraction, scanning and transmission electron microscopy and microhardness measurements.

Determination of optimal microwave curing cycle for fly ash mortars

2008 ◽  
Vol 35 (4) ◽  
pp. 349-357 ◽  
Author(s):  
İlker Bekir Topçu ◽  
Mehmet Uğur Toprak ◽  
Devrim Akdağ
Keyword(s):  
Fly Ash ◽  
Processing Parameters ◽  
Microwave Energy ◽  
Strength Prediction ◽  
Strength Development ◽  
Microwave Curing ◽  
Optimal Processing ◽  
Cement Mortars ◽  
Curing Cycle

Microwave energy can accelerate the hydration of cement, which results in the rapid strength development of concrete. In this paper, prediction of later age compressive strength of fly ash cement mortars, based on the accelerated strength of mortars cured with microwave energy, was investigated. To accelerate curing properly, optimal processing parameters of microwave curing (MC) on Portland cement mortars (CM) and fly ash cement mortars (FA) were first determined and then were applied to mortars. The possible early ages for the strength prediction were found to be at 6 and 8 h for CM and FA, respectively. The error percentages for prediction of CM were ±2.22% and 2.91% for 7 and 28 d, respectively. Error percentages for FA, on the other hand, were ±4.36% and 5.20% for 7 and 28 d, respectively.

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