Fabrication of Micro-Pins by Electrochemical Machining

2013 ◽  
Vol 634-638 ◽  
pp. 2839-2842
Author(s):  
Lih Wu Hourng ◽  
Bing Chi Li ◽  
Chen I Lai
Keyword(s):  
Aspect Ratio ◽  
Applied Voltage ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Limiting Current ◽  
Conical Angle ◽  
Drawing Speed ◽  
Working Parameters ◽  
Surface Precision

The purpose of present paper is to fabricate tungsten rods with diameter of 200 μm to micro-pin electrodes, which have small conical angle and high aspect ratio, by the use of electrochemical machining process. The influence of working parameters, such as: applied voltage, electrolyte concentration, anode depth, and drawing speed on the machining process is investigated. Experimental results show that the applied voltage and electrolyte concentrate will affect the surface precision as the machining current is small than the limiting current. The anode immersed depth combined with a suitable drawing velocity has a significant effect on the conical angle (conicity) and aspect ratio.

Experimental Investigation of Cut Profile in the Electrochemical Drilling of Titanium Alloy

2018 ◽  
Vol 777 ◽  
pp. 327-332
Author(s):  
Ornsurang Netprasert ◽  
Noppakao Chimyo ◽  
Suphaphich Phimphun ◽  
Jantakarn Sukjan ◽  
Viboon Tangwarodomnukun ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Applied Voltage ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Experimental Result ◽  
Drilling Process ◽  
Electrode Gap ◽  
Electrochemical Drilling ◽  
Cut Quality

Electrochemical machining process is an advanced material removal technique offering high precision and introducing no heat damage to the work material. The shape and size of machined area are highly dependent on some process parameters such as voltage, electrolyte and inter-electrode gap. To further enable a more insight into the process performance, this paper investigates the influences of applied voltage, electrolyte concentration and inter-electrode gap on the shape and sizes of hole produced by the electrochemical drilling process. Titanium alloy (Ti-6Al-4V) was used as a work sample in this study as it has been extensively used in many advanced applications. The experimental result indicated that the use of high voltage and high electrolyte concentration can enlarge and deepen hole in the workpiece, while the inter-electrode gap provided less effect to the hole features. The maximum hole depth can reach 300 μm within 60 seconds when the applied voltage of 30 V, the inter-electrode gap of 10 μm and the electrolyte concentration of 10%wt were used. However, with this setup, the obtained cut profile became a non-uniform V-shaped hole. The use of lower voltage was instead recommended to yield a better cut quality with U-shaped profile.

On Performance of Electrochemical Discharge Micro-Machining Process Using Different Electrolytes and Tool Shapes

2020 ◽  
Vol 10 (2) ◽  
pp. 49-63
Author(s):  
Bijan Mallick ◽  
Sumit Biswas ◽  
Biplab Ranjan Sarkar ◽  
Biswanath Doloi ◽  
Bijoy Bhattacharyya
Keyword(s):  
Surface Roughness ◽  
Applied Voltage ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Machining ◽  
Sem Images ◽  
Research Article ◽  
Tool Shape

The electro-chemical discharge micro-machining (µ-ECDM) process can be utilised as a potential micro-machining process, which offers several advantages such as cost-effectiveness and diversity in applications on electrically non-conducting hard brittle materials like glass. The present research article includes the analysis of material removal rate (MRR), width of cut (WOC), heat affected zone (HAZ), and surface roughness (Ra) during µ-channeling on glass with a micro-ECDM process, considering applied voltage (V), electrolyte concentration (wt%), and tool shapes as process parameters. A comparative study is conducted to select the suitable tool shape and electrolyte. Moreover, the optical and SEM images are used to examine HAZ, WOC and topography of µ-channels. MRR and WOC enhance with the rise of applied voltage for fixed electrolyte concentration and vary with tool shape. Surface roughness (Ra) is found low at applied voltage of 55V and 60V for both electrolytes when straight and curved tools, respectively, are used. The straight tool shape is more suitable for µ-channeling on glass by µ-ECDM.

scholarly journals Effect on Material Removal Rate and Surface Finish in ECM Process When Machining Stainless Steel-316 with Cu Electrode

2019 ◽  
Vol 8 (4) ◽  
pp. 2933-2941
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Processes

Electrochemical Machining process is one of the popular non-traditional machining processes which is used to machine materials such as super alloys, Ti-alloys, stainless steel etc. Its working principle is based upon Faraday law of electrolysis. The aim of the present work is to optimize the ECM process parameters with the combination of SS 316 (job material) and Copper electrode (tool material). To explore the effect of ECM process parameters such as electrolyte concentration, voltage and current, feed rate on MRR and surface finish (Ra) of the job, total 27 experiments were conducted as per experimental scheme. The results of these experiments revealed that increase in electrolyte concentration decrease the mrr and surface roughness initially increases then decreases. Further, increase in current increases mrr initially and then decreases, surface roughness also increases. It is also noticed that increase in Feed rate mrr decreases and then increases, also surface roughness decreases then increases. Through RSM analysis it is found that the optimum conditions for maximum MRR, and minimum Surface roughness (Ra) is electrolyte concentration 150gm/lit, Voltage 13.5 V & feed 0.8 mm/min. The findings are discussed in the light of previous researches and subsequently conclusions are drawn.

Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB2in situ composites using the Entropy–VIKOR method

2020 ◽  
Vol 234 (10) ◽  
pp. 1311-1322 ◽  
Author(s):  
S Chandrasekhar ◽  
NBV Prasad
Keyword(s):  
Applied Voltage ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Entropy Method ◽  
Machining Parameters ◽  
Vikor Method ◽  
Electron Microscopic ◽  
Micro Drilling ◽  
Response Optimization

This article describes the multi-response optimization of electrochemical machining operating parameters such as voltage, concentration of the electrolyte, and current to maximize the rate of material removal in addition to minimize the over cut and delamination at the same time in micro-drilling of AA6061-TiB2 in situ composite. A novel Entropy–VIKOR method is applied to handle such mutually conflicting responses. The weight of each response is computed from the entropy method, and VIKOR method is used to rank the various levels of parameters. This method yields the combination of 2 mol of electrolyte concentration, 16 V of applied voltage, and 4 A of current as optimal parameters to minimize the over cut and delamination in addition to maximize the rate of material removal at the same time. This optimal process-governing parameters satisfied the conditions for compromising solution such as acceptable advantage and acceptable stability condition. The response graph illustrates that, of the parameters investigated, electrolyte concentration has the greatest effect on the VIKOR index, followed by applied voltage and current. Scanning electron microscopic analysis illustrates that the radius of the hole is equal throughout the periphery, except for one instance of micro-delamination.

Experimental Investigation and Performance Characteristics Study of Electrolyte in Micro Electrochemical Machining

2015 ◽  
Vol 787 ◽  
pp. 416-420 ◽  
Author(s):  
J. Prakash ◽  
S. Gopalakannan
Keyword(s):  
Sodium Chloride ◽  
Sodium Nitrate ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Performance Characteristics ◽  
Machining Process ◽  
Duty Factor ◽  
Machining Processes ◽  
Pulse On Time

Many advanced machining processes have higher initial investment, maintenance and tooling costs. In these circumstances micro electrochemical machining [µECM] processes meet the requirements with better efficiency and economy. The micro electrochemical machining process parameter such as electrolyte concentration, machine voltage, and pulse on time and duty factor are optimized with considerations of the multiple performance characteristics such as material removal rate (MRR) and overcut. Increase in electrolyte concentration considerably improves MRR but yields a poorer over cut. Increased machine voltage serves to increase both MRR and over cut significantly. Increased pulse on time and duty factor did not have notable impact on MRR and overcut. Less concentration of sodium chloride [NaCl] is sufficient for machining compared with sodium nitrate [NaNO3]. Higher MRR and better over cut are achieved with sodium chloride and moreover it is more economical than sodium nitrate.

scholarly journals MODELLING OF THE OF ELECTROCHEMICAL MACHINING PROCESS

2007 ◽  
Vol 40 (18) ◽  
pp. 475-480
Author(s):  
Laurentiu SLATINEANU ◽  
Oana DODUN ◽  
Loredana SANTO ◽  
Margareta COTEATA ◽  
Adriana MUNTEANU
Keyword(s):  
Electrochemical Machining ◽  
Machining Process

Effect of Electrolyte Concentration on Anodised Titanium in Mixture of β-Glycerophosphate (β-GP) and Calcium Acetate (CA)

2015 ◽  
Vol 1087 ◽  
pp. 116-120 ◽  
Author(s):  
Te Chuan Lee ◽  
Maizlinda Izwana Idris ◽  
Hasan Zuhudi Abdullah ◽  
Charles Christopher Sorrell
Keyword(s):  
Oxide Layer ◽  
Applied Voltage ◽  
Focused Ion Beam ◽  
Electrolyte Concentration ◽  
Ion Beam ◽  
Digital Camera ◽  
Disodium Salt ◽  
Calcium Acetate ◽  
Anode Surface ◽  
Ion Diffusion

Anodic oxidation is a surface modification method which combines electric field driven metal and oxygen ion diffusion for formation of oxide layer on the anode surface. Anodised titanium has been widely use in biomedical applications especially in dental implant. This study aimed to investigate the effect of electrolyte concentration on titanium. Specifically, the titanium foil was anodised in mixture of β-glycerophosphate disodium salt pentahydrate (β-GP) and calcium acetate monohydrate (CA) with different concentration (0.02 M + 0.2 M and 0.04 M + 0.4 M), anodising time (10 min), applied voltage (150, 200, 250, 300 and 350 V) and current density (10 mA.cm-2) at room temperature. Surface oxide properties of anodised titanium were characterised by using glancing angle X-ray diffraction (GAXRD), field emission scanning electron microscope (FESEM), focused ion beam (FIB) milling and digital camera. With increasing electrolyte concentration, the oxide layer became more porous. The GAXRD results also showed that rutile formed at high applied voltage (≥300 V) when the higher concentration of electrolyte was used.

scholarly journals Grey Relational Analysis Optimization of Input Parameters for Electrochemical Discharge Drilling of Silicon Carbide by Gunmetal Tool Electrode

2020 ◽  
Vol 44 (4) ◽  
pp. 239-249
Author(s):  
Pravin Pawar ◽  
Amaresh Kumar ◽  
Raj Ballav
Keyword(s):  
Silicon Carbide ◽  
Grey Relational Analysis ◽  
Electrolyte Concentration ◽  
Research Work ◽  
Machining Process ◽  
Advanced Technology ◽  
Tool Electrode ◽  
Relational Analysis ◽  
Electrochemical Discharge ◽  
Grey Relational

The electrochemical discharge machining process (ECDM) is a hybrid advanced technology integrated with electrochemical and electro-discharge processes has used for the manufacturing of non-conducting along with conducting materials. The silicon carbide is non-conducting material which has widely used in various fields such as automobile, aviation, medical, nuclear reactor, and missile. The machining of silicon carbide is a challenging task by using non-conventional along with conventional machining processes due to its physical properties. The current research work shows the machining of Silicon carbide material by using fabricated ECDM machine setup with gunmetal tool material. The Taguchi L27 orthogonal array technique is applied for experimental work. The grey relational analysis optimization is applied for the investigation of optimum input factors for better output responses. The input process factors like electrolyte concentration, applied voltage, and rotation of tool and outcome results such as machined depth and the diameter of hole were checked after drilling of silicon carbide material. The experimental results indicate the electrolyte concentration is the leading factor for diameter of hole and depth of machined hole subsequent to voltage and tool rotation.

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