Research on Micro Electrochemical Machining Based on Multifunction Machine Tool

2009 ◽  
Vol 628-629 ◽  
pp. 399-404
Author(s):  
Xiao Hai Li ◽  
Li Jie Zhao ◽  
Xin Rong Wang ◽  
X. Zhang ◽  
Zhen Long Wang
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
Short Pulse ◽  
Electrochemical Machining ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Electrode Gap ◽  
Micro Ecm ◽  
Gap Control ◽  
Ultra Short Pulse

The research aims to develop an experimental equipment to carry out in depth research on micro electrochemical machining (micro-ECM). The mechanisms of ultra-short pulse current micro ECM are discussed. As a consequence, lower machining voltage, lower passivity electrolyte concentration, high frequency short pulse power supply and micro rotating tool electrode at high speed have been synthetically used to localize the dissolution area during micro-ECM. The machining gap can be kept at a very small value, and the better resolution of machined shape is achieved by using a novel designed electrode gap control system and the effective utilization of ECM for micromachining is fulfilled. The experiments on microstructure by micro-ECM milling on stainless steel plate are conducted. The micro structures milled on 304 stainless steel foil with 300μm thickness with high precision and high aspect ratio are achieved, and the width of micro beam is about 60μm.

Pulsed Micro-Electrochemical Machining Technology

2007 ◽  
Vol 339 ◽  
pp. 327-331 ◽  
Author(s):  
Xiao Hai Li ◽  
Zhen Long Wang ◽  
W.S. Zhao ◽  
Fu Qiang Hu
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
Short Pulse ◽  
Research Work ◽  
Electrochemical Machining ◽  
Tool Electrode ◽  
Stainless Steel Foil ◽  
Micro Ecm ◽  
Micro Hole ◽  
Micro Tool

This research work aims to explore the feasibility of applying electrochemical machining (ECM) to micromachining. An experimental setup for micro-ECM has been developed. Lower machining voltage, lower concentration of passivity electrolyte, high-frequency short-pulse power supply and micro tool electrode rotating at high speed have been synthetically adopted to localize the dissolution area in micro-ECM, so the machining gap can be kept at about 10 μm and the better resolution of machined shape is achieved. A micro-hole with 45μm diameter is drilled on the stainless steel foil with 100μm thickness. A new approach of fabricating microstructure by micro-ECM milling with a simple micro electrode is proposed, and the micro beam with width of about 50μm which has high precision is fabricated by micro-EC milling on the stainless steel foil (1Cr18Ni9Ti) with 300μm thickness. A mathematics model has been established, which can be used to simulate the process of shaping workpieces in the process of micro-ECM.

Key Technology of Micro Electrochemical Milling Based on Ultra-Short Pulse Current

2014 ◽  
Vol 800-801 ◽  
pp. 838-842
Author(s):  
Xiao Hai Li ◽  
Zhao Ning Sun ◽  
Wu Qi Liu ◽  
Xiao Xia Wang
Keyword(s):  
High Precision ◽  
High Speed ◽  
Pulse Current ◽  
Short Pulse ◽  
Tool Electrode ◽  
Micro Ecm ◽  
Cad Cam ◽  
Micro Tool ◽  
Ultra Short Pulse ◽  
Electrochemical Milling

A new process of fabricating microstructures through micro electrochemical milling (micro EC milling) is proposed. The experiment equipment with a new type of ultra-short pulse supply was developed for micro EC milling. By controlling the movement track of simple micro tool electrode rotating at high speed on NC three-axis feed worktable, microstructures with high precision can be milled by micro-ECM under ultra-short pulse current. Micro EC milling can greatly improve the machining status in the tiny machining gap and thus make machining stable by simple rotary column electrode. The process of the NC generating micro-ECM integrating CAD/CAM technology is studied. G code for machining complex microstructures can be generated by the universal CAD/CAM of traditional milling based on UG software. Last, Microstructures with high precision were milled by this process, for example the micro trench with width of about 50μm.

Research on NC Electrochemical Mechanical Complex Machining Stainless Steel

2010 ◽  
Vol 458 ◽  
pp. 331-336
Author(s):  
Wei Min Gan ◽  
Xi Lian Xie ◽  
Bo Xu ◽  
W.B. Huang
Keyword(s):  
Stainless Steel ◽  
Machine Tool ◽  
Process Parameters ◽  
High Speed ◽  
Orthogonal Experiment ◽  
High Strength ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Tool Electrode ◽  
Feed Speed

For hard machining metal materials with high rigidity，high strength or high toughness, the method of electrochemical mechanical complex machining is proposed. A NC high-speed machine tool for carving and milling is transformed into a NC electrochemical mechanical complex machine tool in which complex tool-electrodes, particular tool holders, a new rotary table, a protective flume for electrolyte and pipelines are made and assembled, so that machine tool can achieve a series of machining, such as milling, drilling, grinding and polishing by utilizing complex tool-electrode motion generated by NC. For 304 stainless steel orthogonal experiment is carried out, and five principal process parameters that are spindle rev, feed speed, voltage, pressure of electrolyte and depth of cut, are investigating in the method of NC Electrochemical Mechanical complex machining. The optimization process parameters are obtained.

scholarly journals Corrosion Resistance of AISI 304 Stainless Steel Modified Both Femto- and Nanosecond Lasers

Coatings ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 592
Author(s):  
Katarzyna M. Mroczkowska ◽  
Paulina Dzienny ◽  
Aleksander Budnicki ◽  
Arkadiusz J. Antończak
Keyword(s):  
Stainless Steel ◽  
Corrosion Resistance ◽  
Surface Layer ◽  
Chemical Composition ◽  
Short Pulse ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Short Pulse Duration ◽  
Ultra Short Pulse

This article is aimed to study the effect of laser treatment of AISI 304 stainless steel on the corrosion resistance and chemical composition of the surface layer. The samples were irradiated using two quite different laser sources: IPG Yb:glass fibre laser (τ = 230 ns, λ = 1062 nm) and Trumpf TruMicro Series 2020 fiber laser (τ = 260 fs–20 ps, λ = 1030 nm) that is, in both the long and ultra-short pulse duration regime. It allowed the observation of completely different microstructures and chemical composition of the surface layer. In this study, the morphology of the samples was accessed using both Keyence digital microscope and Olympus Lext 5000 profilometer. The corrosion resistance was examined in 3% NaCl solution using both potentiodynamic measurement and Electrochemical Impedance Spectroscopy. In order to examine the change in chemical composition of the surface layer, the X-ray photoelectron spectroscopy study was performed. Results show that the use of a long laser pulse contributes to the formation of a thin, tight, rich in chromium passive layer, which significantly improves corrosion resistance in comparison to the reference sample. Different behaviour is observed after irradiation with an ultra-short pulse duration laser.

scholarly journals Computer Simulation of High-Speed Anodic Dissolution Processes of Geometrically-Complex Surfaces of GTE Details

2014 ◽  
Vol 8 (1) ◽  
pp. 436-440 ◽  
Author(s):  
Maxim V. Nekhoroshev ◽  
Nikolay D. Pronichev ◽  
Gennadiy V. Smirnov
Keyword(s):  
Electric Fields ◽  
High Speed ◽  
Rapid Development ◽  
Electrochemical Machining ◽  
Aircraft Engine ◽  
Electrode Spacing ◽  
Work Piece ◽  
Tool Electrode ◽  
Electrode Gap ◽  
Switched Mode Power Supply

Electrochemical machining (ECM) is widely used in modern aircraft engine technology. This method was developed on a step-by-step basis in accordance with development of gas turbine equipment. Introduction of new difficult to machine materials into engines designs and improvement of accuracy of detail geometric parameters required new technological solutions. ECM method has a number of advantages: zero tool wear, the process does not depend on physical-mechanical properties of work piece material, no heat and force action on a work piece; these facts provide high quality of the surface layer and increase engine life. However, electrochemical machining has also disadvantages which essentially limit its applicability. This is primarily a low localization of ECM process. In order to eliminate this disadvantage new ECM schemes were developed, inter-electrode gap was reduced, switched mode power supply units, vibration of electrochemical machining electrode, etc. were used. Electrochemical machines design became more complicated and ECM operations design techniques required new solutions, therefore the scientific inquiry in this area continued intensively. Rapid development of computer technology contributed to the creation of digital models that adequately describe processes in the inter-electrode spacing at ECM. It is necessary to create electronic databases for various electrochemical metal-electrolyte systems, to develop techniques to simulate electric fields in the inter-electrode spacing, and to profile tool electrode automatically. The authors carried out active researches in this area at all stages of ECM development; they have a large number of publications in the field, including 4 monographs.

Research on Micro Electrochemical Milling

2008 ◽  
Vol 375-376 ◽  
pp. 318-322 ◽  
Author(s):  
Xiao Hai Li ◽  
Zhen Long Wang ◽  
Jun Fa Wang ◽  
Xin Rong Wang
Keyword(s):  
High Speed ◽  
Short Pulse ◽  
Influence Factors ◽  
Side Wall ◽  
Tool Electrode ◽  
Feed Speed ◽  
Micro Ecm ◽  
Cad Cam ◽  
Micro Tool ◽  
Electrochemical Milling

A new process of fabricating microstructures through micro electrochemical milling (micro EC milling) is proposed. By utilizing side wall of simple micro tool electrode rotating at high speed like micro mechanical milling and controlling the movement track on NC three-axis feed worktable, microstructures with high precision can be milled by micro-ECM under high-frequency short-pulse current. Micro EC milling can greatly improve the machining status in the tiny machining gap and thus make machining stable by simple rotary column electrode. The influence factors on the accuracy of micro-EC milling were investigated through process experiments, such as feed speed, machining voltage and kind of electrolyte. The process of the NC generating micro-ECM integrating CAD/CAM technology is studied. G code for machining complex microstructures can be generated by the universal CAD/CAM of traditional milling based on UG software. Last, Microstructures with complex shape were milled by this process, for example the micro bend beam with width of about 50μm, and its aspect ratio is about 6.

Explosively Driven Expansion and Fragmentation Behavior for Cylinders, Spheres and Rings of 304 Stainless Steel

2010 ◽  
Vol 638-642 ◽  
pp. 1035-1040 ◽  
Author(s):  
Tetsuyuki Hiroe ◽  
Kazuhito Fujiwara ◽  
Hidehiro Hata ◽  
Mitsuru Yamauchi ◽  
Kiyotaka Tsutsumi ◽  
...  
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
Fracture Behavior ◽  
Copper Wire ◽  
304 Stainless Steel ◽  
Fragmentation Model ◽  
Fragmentation Behavior ◽  
Deformation And Fracture ◽  
Test Parameters ◽  
Fine Copper

Explosive loading techniques are applied to expand tubular cylinders, spherical shells and rings of 304 stainless steel to fragmentation, and the effects of wall thicknesses, explosive driver diameters and the constant proportionality of the in-plane biaxial stretching rates are investigated on the deformation and fracture behavior of three basic structures experimentally and numerically. In the cylinder tests, the driver is a column of high explosive PETN, inserted coaxially into the bore of a cylinder and initiated by exploding a fine wire bundle at the column axis using a discharge current from a high-voltage capacitor bank. In case of the ring tests, ring specimens are placed onto a single cylinder filled with the PETN as a expansion driver, and for sphere tests, specimens filled with the PETN are also initiated by exploding a fine copper wire line with small length located at the central point. Two types of experiments are conducted for every specimen and test condition. The first type uses high speed cameras to observe the deformation and crack generation of expanding specimens showing the final maximum in-plane stretching rate of above , and the second uses soft capturing system recovering typically most fragments successfully. The fragments are measured and investigated using a fragmentation model. The effects of test parameters on the deformation and fracture behavior for three types of structures are discussed in need of modified fragmentation model for shell structural elements.

Wear performance of surface treated drills in high speed drilling of AISI 304 stainless steel

2020 ◽  
Vol 58 ◽  
pp. 223-235
Author(s):  
Sarmad Ali Khan ◽  
Sumbul Shamail ◽  
Saqib Anwar ◽  
Amjad Hussain ◽  
Shafiq Ahmad ◽  
...  
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Wear Performance ◽  
Aisi 304 ◽  
High Speed Drilling

Design and its Experiments of Micro Electrochemical Machining System

2010 ◽  
Vol 97-101 ◽  
pp. 2505-2508 ◽  
Author(s):  
Yuan Bo Li ◽  
Yong Jun Zhang ◽  
Zhong Ning Guo
Keyword(s):  
High Resolution ◽  
Power Supply ◽  
Pulse Width ◽  
Short Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Micro Ecm ◽  
Machining System ◽  
Short Pulse Width

A micro Electrochemical Machining (ECM) system has been developed, and macro/micro complex feed mechanism has been presented in order to achieve high-resolution. A nanosecond pulse power supply for micro-ECM has been developed, and the minimum pulse width can reach 50 ns. Complementary chopper circuit has been designed to avoid waveform distortion, which can achieve higher pulse frequency. A series of ECM experiments using the machining system have been carried out, and results of tests have proved that high-resolution spindle, and high frequency, short pulse width power supply help to achieve better quality surface, higher machining accuracy.

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