Application of Electrochemical Discharge Machining to Micro-Machining of Quartz

2014 ◽  
Vol 939 ◽  
pp. 161-168 ◽  
Author(s):  
Kun Ling Wu ◽  
Hsin Min Lee ◽  
Kuan Hwa Chin
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Processing Parameters ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Process Technology ◽  
Machining Time ◽  
Optimal Processing ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge

Electrochemical discharge machining (ECDM) is the preferred non-traditional process technology in recent years, The main processing is applied to machining non-conductive hard brittle materials. This study investigated the precision and stability of quartz fabricated by ECDM and explored the optimal processing parameters including size of electrode, machining speed as well as pulse-on and pulse-off duration. Microgrooves machined under the optimal processing parameters with adjusted rotational speed and feed rate were examined to understand the effect of different ECDM parameters on machining performance. The results indicate that micro-holes of better morphology could be obtained under pulse voltage of 40 V, electrolyte concentration of 5 M, electrode size of 125 μm. Moreover, rotational speed of 1500 rpm and pulse-on/pulse-off (ms) ratio of 1:0.6 gave higher machining accuracy with smaller hole diameter and shorter machining time. Finally, microgrooves machined under the optimal processing parameters showed the best accuracy in dimension and cross-sectional morphology at rotational speed of 2500 rpm, pulse-on /pulse-off (ms) ratio of 1:1.6, and feed rate of 3000 μm/min.

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.

The Improvement of Machining Accuracy on Quartz and Glasses by Electrochemical Discharge Machining

2014 ◽  
Vol 472 ◽  
pp. 682-687 ◽  
Author(s):  
L.W. Hourng ◽  
C.I. Lin ◽  
B.G. Lee
Keyword(s):  
Surface Roughness ◽  
Electrolyte Concentration ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Film Stability ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Working Parameters ◽  
Applied Voltage Pulse ◽  
Gaseous Bubbles

In the present study, a tungsten rod with diameter of 100μm is used as the tool to drill a quartz plate by Electrochemical Discharge Machining (ECDM). KOH solution mixed with different concentration of Ethanol is used as the electrolyte. The influences of different working parameters, such as electrolyte concentration, applied voltage, pulse frequency, and electrolyte level, on the gas film stability, gas film thickness, and machining accuracy are investigated. The experimental results show that the overcut and surface roughness is improved by the use of electrolyte with addition of 6.5wt% ethanol. The effect of gaseous bubbles is reduced during the machining, and the circulation of electrolyte is better. Compared with machining with pure KOH electrolyte, the overcut is reduced around 57% by the use of electrolyte with addition of 6.5wt% ethanol. The heat-effected zone on the machining is also largely reduced.

Effect of Process Parameters on Defect Formation in Friction Stir Processed 6082-T6 Aluminium Alloy

2012 ◽  
Vol 232 ◽  
pp. 3-7
Author(s):  
Akinlabi Esther Titilayo ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Feed Rate ◽  
Rotational Speed ◽  
Defect Formation ◽  
Processing Parameters ◽  
Friction Stir

This paper reports the effects of processing parameters on defects formed during friction stir processing of 6082-T6 Aluminium Alloy. The plates were processed by varying the feed rate between 50 and 250 mm/min, while the rotational speed was varied between 1500 and 3500 rpm to achieve the best result. It was observed that the sheets processed at the highest feed rate considered in this research resulted in wormhole defect. These processed samples with defects were correlated to the tensile results and it was found that the Ultimate Tensile Strength (UTS) of these samples was relatively low compared to other samples without defects.

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.

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.

Development of Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining Tool

2019 ◽  
Vol 12 (4) ◽  
pp. 313-325
Author(s):  
Xiaokun Li ◽  
Yuankai Ren ◽  
Zhiyuan Wei ◽  
Yong Liu
Keyword(s):  
Machine Tool ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Brittle Materials ◽  
Geometric Accuracy ◽  
Machining Performance ◽  
Machining Quality ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Hard And Brittle Materials

Background: The fabrication of microstructures with high machining quality is always difficult when it is concerned with non-conductive hard and brittle materials such as glass and engineering ceramics. It is reported in related papers and patents that Electrochemical Discharge Machining (ECDM) process is a good choice for machining non-conductive, hard and brittle materials. However, the machining performance of ECDM process, especially in the aspect of geometric accuracy and surface quality, needs to be greatly improved. Objective: The purpose of this study was to improve the machining quality of conventional ECDM process by introducing ultrasonic vibration to ECDM process, develop an Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining (UAECDM) tool, and investigate the improvements of the machining performance by means of comparative experiments. Methods: Firstly, the machining principle of UAECDM was investigated, and the effects of ultrasonic vibration are discussed with the analysis of the micro process. Secondly, the hardware system, which consists of a machine tool body, XY and Z axes, an ultrasonic spindle system and motion control system, was established; and the software system was developed based on the analysis of the overall workflow of the machining process. Finally, comparative experiments, including ECDM drilling, UAECDM drilling, ECDM milling and UAECDM milling, were carried out to reveal the improvements of the machining quality. Results: In the UAECDM group, a micro-hole with the inlet diameter of 133.2µm as well as the 3 × 3 array of micro holes was fabricated on the glass workpiece with 300µm thickness, and a microgroove with the width of 119.2µm was successfully milled on the glass workpiece. It is shown in both microscopic photographs and optical measurements that the microstructures fabricated by UAECDM have better machining quality compared with similar microstructures fabricated by ECDM. Conclusion: Based on comparative experiments and discussions of the results, it has been proved that the machine tool can meet the requirement of the ultrasonic vibration-assisted micro electrochemical discharge machining and can improve the geometric accuracy and surface quality significantly.

Study of Hole-Machining on Pyrex Wafer by Electrochemical Discharge Machining (ECDM)

2006 ◽  
Vol 505-507 ◽  
pp. 1207-1212 ◽  
Author(s):  
Yunn Shiuan Liao ◽  
Wen Yang Peng
Keyword(s):  
Current Pulse ◽  
Feed Rate ◽  
Removal Rate ◽  
Pulse Interval ◽  
Average Current Density ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Gap Control ◽  
Average Current ◽  
Hole Machining

The gap control problem in hole-machining of Pyrex® wafer by electrochemical discharge machining (ECDM) to obtain a smooth quality and acceptable material removal rate is studied. Analysis of the pulse signals shows that the average current pulse interval is constant, and it is mainly related to the ion translation conditions, such as the electrolyte concentration and the flushing strategy. The most steady and intense average current density can be obtained if the voltage on-time is around 3 times the average current pulse interval and the voltage off-time is 1/4 of the on-time for bubble film dissipation. The utmost allowable feed rate at each depth is recorded as the reference of the feed rate in real continuous machining to avoid the damage to the wafer. By applying 80% of the extreme allowable feed rate, 99.9% quality-proved holes can be acquired. The diametric error at the entrance or exit is within 6%. Besides, there is no crater-like problem around the hole that facilitates the succeeding bonding process. This study contributes to the successful production of reusable optical biological chips with integrated micro fluidic channels.

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