Experimental Study on Electrochemical Machining of Conical Micro-Holes

The machining of materials on microscopic scales is considered to be great importance to a wide variety of fields. Electrochemical Micro-machining (EMM) appears to be promising to machine the micro-structures in future due to the material is dissolved at the unit of ion. This paper is focused on developing a micro electrochemical machining system in which the micro-structures such as micro-cylinder, multiple micro-electrodes, micro-holes and micro-slot were processed. The micro-electrodes were prepared in a precisely controlling the electrochemical etching process. Mathematical model controlling the diameters of electrodes was built up. Furthermore, the obtained micro-electrodes were selected as the cathode tool for micro holes drilling and micro-slot milling using pulse power in Micro-ECM.

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Electrochemical Micro Machining of Stainless Steel with Voltage Pulses

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.69-70.219 ◽

2009 ◽

Vol 69-70 ◽

pp. 219-224

Author(s):

Hui Chen ◽

Zhen Long Wang ◽

Zi Long Peng ◽

Ying Huai Dong ◽

Wan Sheng Zhao

Keyword(s):

Stainless Steel ◽

Oxide Layer ◽

Electrochemical Machining ◽

Electrolyte Composition ◽

Machining Parameters ◽

Micro Machining ◽

Short Pulses ◽

Is Research ◽

Micro Holes ◽

Voltage Pulses

The purpose of this paper is to study electrochemical micro machining (ECM) technology on stainless steel. The micro machining of stainless steel is difficult by electrochemical machining, especially in machining deep micro holes, because of an oxide layer formed on the surface. To machining stainless steel, HF is usually used in electrolyte to destabilize the oxide layer. In this paper, ECM of stainless steel by applying short pulses in less toxic and corrosive electrolyte is research. The influence of electrochemical machining parameters such as voltage, current, electrolyte composition to machine stainless steel was investigated. The results showed that the oxide layer can be reduced by adding chloride and complex.

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System Design and Kinematics Simulation of Electrochemical Machining Set-Up for Micro-Holes

First International Conference on Integration and Commercialization of Micro and Nanosystems, Parts A and B ◽

10.1115/mnc2007-21098 ◽

2007 ◽

Author(s):

Jishun Jiang ◽

Zhiyong Li

Keyword(s):

Control Method ◽

Electrochemical Machining ◽

Machining Process ◽

Rectilinear Motion ◽

Micro Machining ◽

Technical Requirements ◽

Kinematics Simulation ◽

Wide Range ◽

Micro Holes ◽

Set Up

Electrochemical micro-machining (EMM) appears to be very promising as a future micro-machining technique, since in many areas of applications, it offers many advantages, which include excellent machining precision and control, high machining rate, perfect surface quality and a wide range of materials that can be machined, regardless of their strength and toughness. At present, electrochemical micro-machining has been applied in the production of some metal workpieces, such as micro-holes, micro-slots and complex 3D surfaces. In this paper, A new electrochemical micro-machining set-up for machining metal micro-holes has been developed. Double level mechanical structure has been applied as the main structure style, which has the advantage of excellent structure rigidity, compact framework dimension as well as perfect maneuverability and maintainability. The control system based on PLC control method has also employed to realize different motion styles for rotating axis, such as uniform velocity rectilinear motion, varying velocity rectilinear motion and cycle rectilinear motion and so on. In order to verify the reliability of this EMM set-up, some test works including static measurement, assembling interferences checking and kinematics simulation have been done. The simulation results demonstrate that the developed EMM set-up for manufacturing metal micro-holes is qualified and can satisfy the technical requirements of electrochemical micro-machining process.

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Experimental Investigation and Parameter Optimization of Micro Holes Machining on Ti-6Al-4V Alloy

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.813-814.332 ◽

2015 ◽

Vol 813-814 ◽

pp. 332-336

Author(s):

R.A. Aravind ◽

Shivakumar Ganesh ◽

Syed Mohammed Yasir ◽

G. Madhan Mohan ◽

Vijayan Krishnaraj ◽

...

Keyword(s):

Experimental Study ◽

Experimental Investigation ◽

Process Parameters ◽

Electric Discharge ◽

Optimum Process ◽

Grinding Process ◽

Taguchi’S Method ◽

Electro Discharge Machining ◽

Micro Holes ◽

Variance Approach

This paper presents an experimental study on the diametrical overcut and taper obtained during the machining of micro holes by electro-discharge machining (EDM). Many trials were taken by machining a 2.0 mm electrolytic copper rod to 0.50 mm under various conditions to analyse the effect of process parameters by wire electric discharge grinding process (WEDG). The optimum process parameters were determined by Taguchi’s method. Then a set of electrodes were produced with the determined optimum process parameters and were used to machine micro holes on Ti-6Al-4V alloy. The diameters of the holes were measured and the effects of various parameters were analysed for the variation in taper and diametrical overcut. The experimental results were analysed using analysis of variance approach.

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PULSED ELECTROCHEMICAL MICRO MACHINING OF INVAR (FE-NI) FILM USING AN ELECTRODE ARRAY

Transactions of the Canadian Society for Mechanical Engineering ◽

10.1139/tcsme-2016-0060 ◽

2016 ◽

Vol 40 (5) ◽

pp. 739-747

Author(s):

Kwang-Ho Chun ◽

Seung-Geon Choi ◽

Eun-Sang Lee

Keyword(s):

Electrochemical Machining ◽

Electrode Array ◽

Laser Machining ◽

Shadow Mask ◽

Micro Machining ◽

Thermal Change ◽

Surface Burning ◽

Change Characteristics ◽

Micro Holes ◽

Manufacturing Methods

Recently, invar (Fe-Ni) material has been applied to OLED shadow masks due to its thermal change characteristics and thermal expansion coefficient. The most widely used manufacturing methods for invar are etching and laser machining, but they have problems like non-machined areas generated by etching and surface burning in laser machining. For this reason, an alternative machining method is necessary. In this study, pulsed electrochemical machining (PECM) has been applied to fabricate an OLED shadow mask. PECM is a highly promising technology for shadow mask manufacturing because it can produce micro-scale and complex tapered holes in one process. A pilot experiment was carried out to find a suitable electrolyte for invar film, and an array of coated Ti electrodes was used to fabricate micro holes.

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Investigation on the Electrochemical Micromachining of Micro Holes with Variable Cross-Section

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.644-650.4927 ◽

2014 ◽

Vol 644-650 ◽

pp. 4927-4931

Author(s):

Kun Wang ◽

Meng Gao ◽

Qi Shen

Keyword(s):

Cross Section ◽

Pulse Width ◽

Electrochemical Machining ◽

Processing Parameters ◽

Variable Cross Section ◽

Electrochemical Micromachining ◽

Variable Cross ◽

Machining Parameters ◽

Micro Holes ◽

Side Gap

Based on the principle of electrochemical, the processing mechanism of electrochemical machining (ECM) micro holes is analyzed and discussed, the processing model is established and the quantitative relationship is presented between the machining side gap and the electrochemical machining parameters (pulse width and pulse period, pulse frequency, duty ratio, etc.), workpiece material parameters and the parameters of the electrolyte, the electric double layer equivalent circuit constant with mathematical expression. On the basis of the analysis of the effect of processing parameters on the electrochemical machining accuracy and stability, process out the variable cross-section micro hole at an appropriate processing parameters of variable pulse width.

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Micro-Hole Machined by Electrochemical Discharge Machining (ECDM) with High Speed Rotating Cathode

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.295-297.1794 ◽

2011 ◽

Vol 295-297 ◽

pp. 1794-1799 ◽

Cited By ~ 9

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.

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Mathematical Modeling and Experimental Study on Electrochemical Deburring of Miniature Holes

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.721.382 ◽

2013 ◽

Vol 721 ◽

pp. 382-386 ◽

Cited By ~ 1

Author(s):

Ze Fei Wei ◽

Xing Hua Zheng ◽

Zi Yuan Yu

Keyword(s):

Mathematical Modeling ◽

Experimental Data ◽

Mathematical Model ◽

Finite Element Analysis ◽

Experimental Study ◽

Finite Element ◽

Electrochemical Machining ◽

Current Density Distribution ◽

Element Analysis ◽

The Finite Element Analysis

The paper mainly focused on burr removal of the miniature hole drilled on aluminum plate by electrochemical machining. A mathematical model for the electrochemical deburring of miniature holes (M-ECD) was established based on the finite element analysis to the current density distribution. Both theoretical analysis and experimental study were held on the effects of many factors to the deburring results. The results proved that predictions based on our mathematical model were agreed with the experimental data comparatively.

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