Electrochemical drilling of deep and small holes with high speed micro electrode

2014 ◽  
Vol 22 (3) ◽  
pp. 608-615 ◽  
Author(s):  
刘勇 LIU Yong ◽  
曾永彬 ZENG Yong-bin
Keyword(s):  
High Speed ◽  
Electrochemical Drilling ◽  
Small Holes

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 Study of High-Speed Mechanical Micro Drilling Process Fundamentals for Small Holes

2020 ◽  
Vol 1575 ◽  
pp. 012179
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Siying Ling ◽  
Guangming Zheng ◽  
Hisham Manea
Keyword(s):  
High Speed ◽  
Drilling Process ◽  
Micro Drilling ◽  
Small Holes

Electrochemical drilling of multiple small holes with optimized electrolyte dividing manifolds

2017 ◽  
Vol 247 ◽  
pp. 40-47 ◽  
Author(s):  
Fang Xiaolong ◽  
Wang Xindi ◽  
Wang Wei ◽  
Qu Ningsong ◽  
Li Hansong
Keyword(s):  
Electrochemical Drilling ◽  
Small Holes

scholarly journals Electrochemical Drilling of Deep Small Holes in Titanium Alloys with Pulsating Electrolyte Flow

2014 ◽  
Vol 6 ◽  
pp. 167070 ◽  
Author(s):  
Yongbin Zeng ◽  
Xiaolong Fang ◽  
Yudong Zhang ◽  
Ningsong Qu
Keyword(s):  
Titanium Alloys ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Pulsation Frequency ◽  
Average Pressure ◽  
Electrolyte Flow ◽  
Product Removal ◽  
Electrochemical Drilling ◽  
By Products ◽  
Small Holes

Inherent characteristics of electrochemical drilling (ECD) mean that it is a major solution to the machining of deep small holes in difficult-to-cut materials. The removal of insoluble by-products from the machining gap determines the accuracy of control and limits process capacity. Pulsating electrolyte flow is introduced to enhance the removal rate of insoluble products by reducing the hold-down pressure caused by the electrolyte. Experiments are conducted to optimize a stimulus signal for the pulsation and to investigate the electrolyte pulsation frequency, pulsation amplitude, applied voltage, and electrode feed rate in the machining of deep small holes. The results indicate that optimized pulsating flow is effective in accelerating by-product removal and enhancing machining accuracy and maximum machining depth. With the optimized parameters of 5 Hz in frequency, 0.2 MPa in amplitude, and 0.5 MPa in average pressure, a deep hole was machined in titanium alloys of 20 mm depth and 1.97 mm averaged diameter.

scholarly journals Fabrication of Taper Free Micro-Holes Utilizing a Combined Rotating Helical Electrode and Short Voltage Pulse by ECM

Micromachines ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 28 ◽  
Author(s):  
Yong Liu ◽  
Minghong Li ◽  
Jingran Niu ◽  
Shizhou Lu ◽  
Yong Jiang
Keyword(s):  
Voltage Pulse ◽  
High Speed ◽  
Manufacturing Industry ◽  
Difficult Problem ◽  
Machining Accuracy ◽  
Gap Flow ◽  
Electrochemical Drilling ◽  
Micro Holes ◽  
Micro Hole ◽  
Helical Electrode

Fabrication of the injection nozzle micro-hole on the aero engine is a difficult problem in today’s manufacturing industry. In addition to the size requirements, the nozzle micro-hole also requires no burr, no taper and no heat-affected zone. To solve the above problem, an ultra-short voltage pulse and a high-speed rotating helical electrode were used in electrochemical drilling (ECD) process. Firstly, a theoretical model of ECD with ultra-short voltage pulse was established to investigate the effects of many predominant parameters on machining accuracy, and the effect of rotating helical electrode on the gap flow field was analyzed. Secondly, sets of experiments were carried out to investigate the effects of many key parameters on machining accuracy and efficiency. Finally, the optimized parameters were applied to machine micro holes on 500 μm thickness of GH4169 plate, and micro-holes with the diameter of 186 μm with no taper were machined at the feed rate of 1.2 μm/s. It is proved that the proposed ECD process for fabricating micro-holes with no taper has a huge potential and broad application prospects.

Experimental Study on Electrochemical Drilling of Micro Holes with High Aspect Ratio

2014 ◽  
Vol 941-944 ◽  
pp. 1952-1955 ◽  
Author(s):  
Yong Liu ◽  
Shao Fu Huang
Keyword(s):  
Aspect Ratio ◽  
High Speed ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Drilling Process ◽  
Electrochemical Drilling ◽  
Drilling Technology ◽  
Micro Holes ◽  
Machining System ◽  
Rotary Speed

It is a difficult problem to fabricate deep and micro holes on the difficult-to-cut metals in the field of aviation manufacturing. The experimental research of electrochemical drilling technology with high-speed micro electrode for fabricating deep micro holes is carried out. The influences of rotary speed on machining precision and stability are studied. The holes, which the diameter is about 400μm, the aspect ratio is more than 10, and have steep wall and sharp edges were fabricated successfully on the nickelbase superalloys on self-developed high-precision micro-electrochemical machining system. It is proved that the high-speed electrochemical drilling process for fabricating deep and micro holes has a huge potential and broad application prospects.

Criterion equation for calculation of the current limiting electrochemical machining by formation of sparks

1981 ◽  
Vol 46 (11) ◽  
pp. 2788-2794 ◽  
Author(s):  
Petr Novák ◽  
Ivo Roušar ◽  
Václav Cezner ◽  
Vladimír Mejta
Keyword(s):  
Critical Current Density ◽  
Critical Current ◽  
Current Density ◽  
Electrochemical Machining ◽  
Average Error ◽  
External Insulation ◽  
Electrochemical Drilling ◽  
Criterion Equation ◽  
Current Limiting ◽  
Small Holes

The current density used in electrochemical machining can be increased only up to a certain value, above which the formation of electric sparks on the cathode (tool) is observed, whereby the latter and its insulation are damaged. The present work is devoted to the measurement of this critical current density for the case of electrochemical drilling of small holes by means of metal capillaries provided with an external insulation. The results are correlated by a criterion equation which gives the values of the limiting currents for sparking, IS , with an average error of ±9%.

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