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.

Influence of Electrolytic Products in Machining Gap on Micro ECM

2009 ◽  
Vol 60-61 ◽  
pp. 388-393 ◽  
Author(s):  
Xiao Yu Ma ◽  
Yong Li ◽  
Shan Jin Lv
Keyword(s):  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Efficiency ◽  
Electrode Distance ◽  
Machining Speed ◽  
Micro Ecm

Electrolytic products are hard to be removed from the machining gap in micro ECM (electrochemical machining) process, which may lower the machining speed or even stop the machining process. Intermittent withdrawal of electrode is an effective way to cleanse electrolytic products, renew electrolyte in the gap, and promote the continuance of machining process. The influence of electrolytic products’ removal rate upon machining speed is analyzed in the case of intermittent withdrawal of electrode. Results show that the machining speed does not increase monotonously with the decrease of inter-electrode distance. Considering machining efficiency and accuracy, machining gap should be the corresponding gap value when the machining speed reaches its maximum.

Study on Gap Phenomena Before and After the Breakout Event of Fast Electrical Discharge Machining Drilling

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Weiwen Xia ◽  
Yaou Zhang ◽  
Mo Chen ◽  
Wansheng Zhao
Keyword(s):  
Fluid Flow ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Deep Understanding ◽  
Tool Electrode ◽  
Machining Efficiency ◽  
Short Period ◽  
Before And After ◽  
Flush Fluid ◽  
Side Gap

Abstract Fast electrical discharge drilling is broadly used to manufacture small holes on molds, dies, filters, and automobile and aerospace components. Breakout is the event when the tool electrode reaches the opposite surface of the workpiece. When a breakout happens, the machining efficiency drops sharply and the process becomes unstable. To gain a deep understanding of the breakout process, this paper observed the gap phenomena before and after the breakout with cameras through a quartz glass flake. Experiments were conducted on the workpiece tilted to 45 deg. From the observation, it was found that the deformation of the electrode was not negligible. The electrode would vibrate or shake before and after the breakout. Side-gap sparks were common in the process, and even more were observed after the breakout. The fluid flow in the discharge gap and the side gap did not vanish immediately when a breakout happened and could still evacuate debris for a short period. The debris gradually accumulated as the fluid flow in the gap vanished. A series of simulations were conducted to study the fluid flow and debris movement after the breakout. And simulations were also performed to find the influence on electrode vibration of high-pressure flush fluid and discharge location. The results of simulations agreed well with the observed phenomena. From the observation and simulation results, the deformation or vibration of the electrode and the accumulation of debris were found to be the main factors that led to the low machining efficiency after the breakout.

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.

scholarly journals The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

2021 ◽  
Vol 5 (2) ◽  
pp. 34
Author(s):  
Guangxian Li ◽  
Ge Wu ◽  
Wencheng Pan ◽  
Rizwan Abdul Rahman Rashid ◽  
Suresh Palanisamy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Machining Efficiency ◽  
Crater Wear ◽  
Wear Process ◽  
High Speed Turning ◽  
Tools Wear ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

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 Experimental Research on Discharge Forming Cutting-Electrochemical Machining of Single-Crystal Silicon

2021 ◽  
Vol 2021 ◽  
pp. 1-13
Author(s):  
Bin Xin ◽  
Wei Liu
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Single Crystal Silicon ◽  
Recast Layer ◽  
Movement Speed ◽  
Crystal Silicon ◽  
Wedm Process

During the wire electrical discharge machining (WEDM) process, a large number of discharge pits and a recast layer are easily generated on the workpiece surface, resulting in high surface roughness. A discharge forming cutting-electrochemical machining method for fabricating single-crystal silicon is proposed in this study to solve this problem. On the same processing equipment, single-crystal silicon is first cut using the discharge forming cutting method. Second, electrochemical anodic reaction technology is used to dissolve the discharge pits and recast layer on the single-crystal silicon surface. The machining mechanism of this process, the surface elements of the processed single-crystal silicon and a comparison of the kerf width are analyzed through experiments. On this basis, the influence of the movement speed of the copper foil electrode during electrochemical anodic dissolution on the final surface roughness is qualitatively analyzed. The experimental results show that discharge forming cutting-electrochemical machining can effectively eliminate the electrical discharge pits and recast layer, which are caused by electric discharge cutting, on the surface of single-crystal silicon, thereby reducing the surface roughness of the workpiece.

Study on Technology of Block Electro-Discharge Grinding with Lower Working Voltage for Fabricating Micro Electrode

2008 ◽  
Vol 375-376 ◽  
pp. 303-307
Author(s):  
Zhen Long Wang ◽  
Wei Liang Zeng ◽  
Qiang Gao
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Slenderness Ratio ◽  
Threshold Value ◽  
Micro Machining ◽  
Minimum Diameter ◽  
Micro Electrical Discharge Machining ◽  
Machining Speed ◽  
And Control ◽  
Working Efficiency

Micro electrical discharge machining (EDM) with block electro discharge grinding (BEDG), is explored and assessed as a method for developing micro electrode, for wire electro discharge grinding (WEDG) has shortcoming of low working efficiency, especially in the case of micro machining. For fabricating micro electrode by BEDG, mechanics of initial clamping errors are analyzed, the technology of electrode movement is proposed to compensate the clamping errors and control the finish size of micro electrodes. On the basis of a great deal of experiments, the effect of working voltage on machining efficiency has been found out and been analyzed theoretically, threshold value of working voltage is determined to be about 30V.As shown by result with the technology, at a high machining speed, the minimum diameter of micro electrodes reaches 3*m, its slenderness ratio is more than 5.

scholarly journals Evaluating Optimal Parameters for Machining Selective Laser Melting Titanium Alloy Using Wire Cut Electrical Discharge Machining

2020 ◽  
Vol 10 (3) ◽  
pp. 62-72
Author(s):  
Ashwin Polishetty ◽  
Guy Littlefair
Keyword(s):  
Titanium Alloy ◽  
Selective Laser Melting ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Chemical Reactivity ◽  
Laser Melting ◽  
Machining Speed ◽  
Wire Feed

Titanium is known for its poor machinability characteristics due to its low thermal conductivity and high chemical reactivity. This article explores the machinability characteristics of selective laser melting (SLM) titanium alloy Ti-6Al-4V using wire cut electrical discharge machining (WEDM). For titanium alloys, exploring non-traditional machining operation such as WEDM is critical for a material failure or success in a design application. The research is to study the effect of parameters such as servo voltage, pulse on/off, and machining speed with respect to wire tension and wire feed rate on machinability. The outputs under consideration for evaluating machinability are metal removal rate (MRR) and surface finish under minimal interruption due to wire snaps. The article concludes by identifying the optimal factors responsible to produce an efficient and accurate cut with a minimum downtime.

Study on the improvement of the surface integrity and efficiency of electrical-discharge-machined TC4 titanium alloy via abrasive flow machining

2020 ◽  
pp. 095440542097109
Author(s):  
Ze Yu ◽  
Dunwen Zuo ◽  
Yuli Sun ◽  
Guohua Li ◽  
Xuemei Chen ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Small Hole ◽  
Machining Process ◽  
Machining Efficiency ◽  
Abrasive Flow Machining ◽  
Tc4 Titanium Alloy

To simultaneously optimize the surface quality and machining efficiency of the electrical discharge machining (EDM) processes used to produce titanium alloy quadrilateral group small hole parts, a combined “EDM + AFM” machining technology is proposed in this paper as an efficient and high-quality machining approach. In the proposed method, TC4 titanium alloy is first machined using the EDM process with graphite electrodes and the abrasive flow machining (AFM) process is then used to finish the machined surface. The effects of various electrical parameters on EDM-derived surface quality and improvements in EDM-derived quality under the application of AFM were assessed and, using the final surface roughness as a constraint condition, the effects of various combinations of EDM and “EDM + AFM” on efficiency were studied. The results revealed that the thickness and surface roughness of the superficial recast layer of the TC4 titanium alloy increase with both current and pulse width; in particular, increasing these parameters can increase the surface roughness by two to three grades. Following AFM, the alloy has a more uniform hardness distribution and the surface stress state changes from tensile to compressive stress, indicating that the combined “EDM + AFM” machining scheme can significantly enhance the surface quality of EDM-produced titanium alloy quadrilateral small group holes. The combined scheme achieves a balancing point beyond which increasing the roughness or the number of machining holes enhances either the machining efficiency or the machining surface quality. In the case of typical titanium alloy quadrilateral group small hole parts, the combined machining process can improve the finishing efficiency and total machining efficiency by 71.2% and 25.36%, respectively.

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