Process Design in Pulse Electrochemical Machining Based on Material Specific Data – 1.4301 and Electrolytic Copper as an Example

2015 ◽  
Vol 651-653 ◽  
pp. 732-737
Author(s):  
Philipp Steuer ◽  
Andreas Rebschläger ◽  
Alexander Ernst ◽  
Dirk Bähre
Keyword(s):  
Process Design ◽  
Electrochemical Machining ◽  
Industrial Applications ◽  
Machining Process ◽  
Constant Current ◽  
Tool Electrode ◽  
Specific Data ◽  
Pulse Electrochemical Machining ◽  
Electrolytic Copper ◽  
Pulse On Time

The Pulse Electrochemical Machining Process is an innovative, non-conventional process, based on the Electrochemical Machining process. Herein, pulsed current instead of constant current and a feed overlaid mechanical vibration of the tool electrode allows a higher precision and copying accuracy in contrast to the well-established ECM process. Yet, in this context the pulse-pause time and the length of the pulse on-time used in the process cause changes in the material removal while processing and therefore influences the processing result as well as cycle times and other industry relevant criteria. Understanding these pulse- and process specific changes is a key to the process design for industrial applications, since different sets and variations in parameters also change the final form and surface topography. This contribution shows, at the example of two materials 1.4301 and electrolytic copper, how a machining process can be designed and calculated based on material specific data. The way to acquire the necessary material data sets using industrial equipment, as well as the use and information which can be drawn from the data will be addressed.

Small Diameter External Cylindrical Surfaces Obtained by Ram Electrical Discharge Machining

2014 ◽  
Vol 611-612 ◽  
pp. 650-655 ◽  
Author(s):  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Hans Peter Schulze ◽  
Oana Dodun ◽  
Irina Besliu ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Analysis ◽  
Electrical Discharge Machine ◽  
Small Diameter ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Electrical Discharges ◽  
Pulse On Time

Electrical discharge machining uses the pulse electrical discharges generated between the closest asperities existing on the workpiece surface and the active surface of the tool electrode in dielectric fluid. Essentially, some distinct electrical discharge machining schemas could be used in order to obtain cylindrical external surfaces; within this research, one preferred a machining schema based on the use of a cooper plate in which there were small diameter holes, by taking into consideration the existence of a ram electrical discharge machine. The results of the machining process analysis were presented. A thin copper was considered to be used as tool electrode, in order to diminish the spurious electrical discharges, able to generate shape errors of the machined surface. Some experimental researches were developed by changing the sizes of the process input parameters. As output factors, the test piece and tool electrode masses decreases were considered. Power type empirical mathematical models were determined, in order to highlight the influence exerted by the pulse on time, off time and machining process duration on the output parameters values.

Experimental study of an electrostatic field–induced electrolyte jet electrical discharge machining process

2015 ◽  
Vol 231 (10) ◽  
pp. 1752-1759 ◽  
Author(s):  
Zhang Yaou ◽  
Han Ning ◽  
Kang Xiaoming ◽  
Zhao Wansheng ◽  
Xu Kaixian
Keyword(s):  
Electrostatic Field ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Cyclic Process ◽  
Tool Electrode ◽  
Series Of Experiments ◽  
Current Detection ◽  
Electrolyte Jet

In this study, a new electrostatic field–induced electrolyte jet electrical discharge machining method has been proposed, which can automatically generate the tool electrode. Then, a series of experiments have been carried out to reveal the machining mechanism and test the machining ability of this method. The continuous observation experiments and the online current detection experiments have demonstrated that the electrolyte jet discharge machining is a pulsing, dynamic and cyclic process. Moreover, the 20-min time long reverse polarity experiments on the silicon surface have revealed that the machining is an electrical discharge machining process during the negative polarity machining; however, in the positive polarity machining, it is a hybrid electrical discharge machining and electrochemical machining process. Furthermore, the craters as small as 2 µm in diameter on stainless steel and silicon are produced by this electrolyte jet electrical discharge machining, which has proved the micro-machining ability of this method.

Study of Pulse Electrochemical Machining Performance of Deep-Small Hole on Nickel-Based Alloy

2011 ◽  
Vol 204-210 ◽  
pp. 1830-1834
Author(s):  
Zhao Long Li ◽  
Shi Chun Di
Keyword(s):  
Base Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Math Model ◽  
Technical Parameters ◽  
Pulse Electrochemical Machining ◽  
Small Holes

The method of machining deep hole on Ni-base alloy which can tolerant high temperature by pulse electrochemical machining has been proposed in this paper. Five technical parameters are discussed on the effect of mass removal rate of machining process. Establish a dynamic math model, and analyze the effect of process parameters on the mass material removal rate of deep small holes. Machining accuracy of deep small holes was analyzed.

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

Study the Surface Characteristics of Cryogenically Treated Tool-Electrodes in Powder Mixed Electric Discharge Machining Process

2014 ◽  
Vol 808 ◽  
pp. 19-33 ◽  
Author(s):  
Sanjeev Kumar ◽  
Rupinder Singh ◽  
Ajay Batish ◽  
T.P. Singh
Keyword(s):  
Electric Discharge ◽  
Surface Characteristics ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Material Transfer ◽  
Electric Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

The present experimental study has been focused to evaluate surface characteristics of cryogenically-treated (shallow/deep) tool-electrodes using powder mixed electric discharge machining. Due to the continuously growing demand of complex and precise parts, tool-electrodes have its own importance, because quality of the machined parts depends upon the surface quality of electrode. On the analogy, eighteen experiments were performed based on L18orthogonal array of Taguchi’s methodology, which consist eight input parameters. Analysis of variance (ANOVA) was employed to designate the level of significance of input parameters. Electrode material has maximum influence followed by the current and pulse on-time on electrode finish. The combination of optimum factor’s level of identified parameters was determined using Taguchi’s technique for single response. Confirmation experiments were conducted using suggested optimal parameters with its respective level to minimize the tool-electrode surface roughness. Surface characteristics of tool-electrodes were analyzed using Scanning Electron Microscope (SEM) and Energy Dispersive Spectrograph (EDS) followed by X-ray diffraction (XRD) on selected samples. The results exposed that significant material transfer from workpiece and powder mixed dielectric fluid in compound form on the tool surface.

scholarly journals Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
T. Praveena Gopinath ◽  
J. Prasanna ◽  
C. Chandrasekhara Sastry ◽  
Sandeep Patil
Keyword(s):  
Magnetic Field ◽  
Titanium Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Micro Hole ◽  
Neodymium Magnets ◽  
Pulse On Time

Abstract An attempt has been made to study the influence of magnetic field on the micro hole machining of Ti-6Al-4V titanium alloy using electrochemical micromachining (ECMM) process. The presence of magneto hydro dynamics (MHD) is accomplished with the aid of external magnetic field (neodymium magnets) in order to improve the machining accuracy and the performance characteristics of ECMM. Close to ideal solution for magnetic and nonmagnetic field ECMM process, the parameters used are as follows: concentration electrolyte of 15 g/l; peak current of 1.35 A; pulse on time of 400 s; and duty factor of 0.5. An improvement of 11.91–52.43% and 23.51–129.68% in material removal rate (MRR) and 6.03–21.47% and 18.32–33.09% in overcut (OC) is observed in ECMM of titanium alloy under the influence of attraction and repulsion magnetic field, respectively, in correlation with nonmagnetic field ECMM process. A 55.34% surface roughness factor reduction is ascertained in the hole profile in magnetic field-ECMM in correlation with electrochemical machined titanium alloy under nonmagnetic field environment. No machining related stress is induced in the titanium alloy, even though environment of electrochemical machining process has been enhanced with the presence of magnetic field. A slight surge in the compressive residual factor, aids in surge of passivation potential of titanium alloy, resulting in higher resistance to outside environment.

Scanning Micro-Electrochemical Machining Process for V-Shaped Grooves

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Hao Zhong ◽  
Hao Tong ◽  
Zhiqiang Wang ◽  
Yong Li ◽  
Yubin Pu
Keyword(s):  
Electrical Discharge Machining ◽  
High Surface ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Tool Electrode ◽  
Microfluidic Chips ◽  
Long Distance ◽  
High Surface Quality ◽  
Micro Electrical Discharge Machining ◽  
The Given

Abstract Microstructures determine flow properties of microfluidic chip. Micromold forming is an effective method to realize mass manufacturing of microfluidic chips. This requires to machine some kind of special microstructure of high surface quality on a metal/alloy workpiece. Micro V-shaped grooves are the typical microstructures of the chip micromolds used for controlling microfluid or weld packaging. In this research, a scanning micro-electrochemical machining (ECM) process of V-shaped grooves is proposed using a tool electrode fabricated by micro–electrical discharge machining (EDM) on-machine. Theoretical and experimental research was conducted for achieving the V-shaped grooves with a given angle on die steel. A long-distance V-shaped groove with the given angle of 67 deg and the depth of 125 μm was successfully machined.

Modeling and Response Optimization of Traveling Wire Electro-Chemical Spark Machining of Borosilicate Glass Using Hybrid Approach

2020 ◽  
Vol 19 (03) ◽  
pp. 425-447
Author(s):  
Basanta Kumar Bhuyan ◽  
Pravabati Bhuyan ◽  
Satish Mishra
Keyword(s):  
Borosilicate Glass ◽  
Removal Rate ◽  
Hybrid Approach ◽  
Kerf Width ◽  
Machining Process ◽  
Tool Electrode ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Traveling Wire

Traveling Wire Electro-Chemical Spark Machining (TW-ECSM) process is a new innovative thermal erosion-based machining process suitable for cutting electrically nonconductive materials using tool electrode in the form of wire. This article attempts experimental modeling of TW-ECSM process using a hybrid methodology comprising Taguchi methodology (TM) and response surface methodology (RSM). The experiments were carried out on borosilicate glass using L[Formula: see text] orthogonal array (OA) considering the input parameters like applied voltage, pulse on-time, pulse off-time, electrolyte concentration and wire feed velocity along with process performances such as material removal rate (MRR), surface roughness (R[Formula: see text] and kerf width (K[Formula: see text]. The interaction influence of input parameters on process performances was also discussed. Further, multi-objective optimization (MOO) of response performances of TW-ECSM process is executed using a coupled approach of grey relational analysis (GRA) and principal component analysis (PCA). The optimal process parameter setting illustrates the improvement of MRR by 171%, diminution of Ra and K[Formula: see text] by 27% and 8% against the initial parameter settings. Moreover, irregular cutting of kerf width and surface characteristics were also scrutinized using scanning electron microscope (SEM).

scholarly journals Effect on Machined Surface Characterization during ECM of AISI 304 Steel

2020 ◽  
Vol 9 (1) ◽  
pp. 1996-2001
Keyword(s):  
Surface Characterization ◽  
Research Work ◽  
Electrochemical Machining ◽  
Steel Production ◽  
Industrial Applications ◽  
Machining Process ◽  
Machined Surface ◽  
Aisi 304 ◽  
Chrome Steel ◽  
Aisi 304 Steel

AISI 304 chrome steel which is extensively used practically altogether industrial applications is represented about half of world’s chrome steel production and consumption. Due to its aesthetic view in architectures, prevalent mechanical and physical properties, weld capacity, obstruction against consumption and synthetic concoctions, it becomes as the most favored material. ECM is one of the most effective machining process because of its capacity to create totally tranquil machine parts with no need of the further completing procedure. In this paper gives the knowdge about the electrochemical machining of AISI 304 steel. Approach of the investigates are done by using Taguchi methodology to study the surface roughness, micro hardness and microstructure. Process parameters such as electrolyte concentration, electrolyte flow rate, applied voltage and feed rate has been optimized by the ANOVA using. This research work supports the industrialist for choosing parameters to accomplish anticipated outputs.

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