A review of physical experimental research in jet electrochemical machining

Kendall, Thomas; Bartolo, Paulo Jorge Da Silva; Gillen, D.; Diver, Carl

doi:10.1007/s00170-019-04099-x

Cited by 29 publications

(12 citation statements)

References 50 publications

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“…Applied voltage (V) 3.5, 6.5 Inter-electrode gap (IEG) (mm) 0.6, 0.9 Electrolyte flow rate (ml min hydroxide precipitation which deteriorates the surface roughness and the stability of Jet-ECM. 41,42 In the Cu ECP process, phosphoric acid is needed to generate a viscous film with high electrical resistance at the interface of the workpiece and electrolyte. 12,13 Also, to gain better surface quality, specific additives such as ethanol, lactic acid, ammonium acetate, and benzotriazole are added to the electrolyte.…”

Section: Parameters Valuementioning

confidence: 99%

“…This phosphoric-based electrolyte has a much higher viscosity (23.5 mm 2 s −1 ) than traditional aqueous electrolytes, and is thus beneficial to achieve good surface quality based on Jacquet theory. 12,19 Also, acid electrolytes can dissolve the metal without the sludge deposition, 41,42 and make it possible to achieve high machining accuracy and stability in Jet-ECM. ECP was adopted as a subsequent process to reduce the surface roughness without affecting the surface PV value.…”

Section: Parameters Valuementioning

confidence: 99%

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Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

Wang

Yan

Zhou

et al. 2020

J. Electrochem. Soc.

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Ultra-flat and ultra-smooth copper (Cu) surfaces are widely used as optical mirrors, heat sinks, and substrates for functional material growth. Traditional polishing methods that rely on abrasive particles are easy to induce mechanical defects such as abrasives embedding and scratches on surfaces. A new stress-free machining process is proposed in this research to fabricate an ultra-flat and ultra-smooth Cu surface by combining jet electrochemical machining (Jet-ECM) and electrochemical polishing (ECP). With the accurate manipulating of material removal rate (MRR) and planning of nozzle trajectory, an ultra-flat surface can be obtained efficiently in the Jet-ECM process. The surface roughness of the workpiece can be further improved by ECP with the same electrolyte used in the Jet-ECM process. The results show that the surface peak-to-valley (PV) value which indicated the surface form error of the Cu surface was reduced from 4.4 μm to 1.7 μm and the surface roughness Sa was reduced from 70.3 nm to 13.5 nm. The combination of Jet-ECM and ECP which share the same electrolyte and apparatus can improve the surface flatness and roughness significantly. This study improves the machining accuracy of stress-free machining methods and has great implications for the further understanding of the electrochemical removal mechanism.

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Section: Parameters Valuementioning

confidence: 99%

Section: Parameters Valuementioning

confidence: 99%

Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

Wang

Yan

Zhou

et al. 2020

J. Electrochem. Soc.

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show abstract

“…In addition to the chemical stability of the material itself due to its intrinsic atomic structure, one principal cause is the easy formation of the passive layer. This kind of material readily combines with oxygen to form a high-resistance oxide film on its surface, thus becoming passivated and significantly hindering the progress of electrochemical machining [15,16]. Therefore, in-process removal of the passive layer becomes indispensable, and several approaches have been proposed.…”

Section: Introductionmentioning

confidence: 99%

Plasma-enabled electrochemical jet micromachining of chemically inert and passivating material

Zhan

Liu

et al. 2022

Int. J. Extrem. Manuf.

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Electrochemical jet machining (EJM) encounters significant challenges in the microstructuring of chemically inert and passivating materials because an oxide layer is easily formed on the material surface, preventing the progress of electrochemical dissolution. This research demonstrates for the first time a jet-electrolytic plasma micromachining (Jet-EPM) method to overcome this problem. Specifically, an electrolytic plasma is intentionally induced at the jet-material contact area by applying a potential high enough to surmount the surface boundary layer (such as a passive film or gas bubble) and enable material removal. Compared to traditional EJM, introducing plasma in the electrochemical jet system leads to considerable differences in machining performance due to the inclusion of plasma reactions. In this work, the implementation of Jet-EPM for fabricating microstructures in the semiconductor material 4H-SiC is demonstrated, and the machining principle and characteristics of Jet-EPM, including critical parameters and process windows, are comprehensively investigated. Theoretical modeling and experiments have elucidated the mechanisms of plasma ignition/evolution and the corresponding material removal, showing the strong potential of Jet-EPM for micromachining chemically resistant materials. The present study considerably augments the range of materials available for processing by the electrochemical jet technique.

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“…They demonstrated that metal wire electrode ECT was a universal and practical technique [17]. Kendall et al found that ECT could play an important role in machining of micro parts via comprehensive analysis of jet electrochemical machining [18].…”

Section: Introductionmentioning

confidence: 99%

Flow field simulation and experimental investigation on macro electrolyte jet electrochemical turning of TB6 titanium alloy

Liu

Qiu

2022

Int J Adv Manuf Technol

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Electrolyte jet electrochemical turning is an effective method to realize high-quality machining of titanium alloy rotating components; however, minimal research has been carried out in this field. This is because it is difficult to control the machining flow field, which leads to poor machining surface quality. In this work, numerical simulations were used to optimize the machining flow field and reduce the proportion of gas that mixed into the machining area. This can promote participation of the tool electrode tip in the electrochemical reaction and improve the machining efficiency. The effectiveness of the optimized machining flow field for jet electrochemical turning was verified experimentally. The results showed that all three kinds of revolving TB6 titanium alloy samples with different structures could maintain the original contour shape, with a contour error <1% and a machined surface roughness reaching Ra 2.414 μm. The results demonstrate the application potential of the jet electrochemical turning process.

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A review of physical experimental research in jet electrochemical machining

Cited by 29 publications

References 50 publications

Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

Plasma-enabled electrochemical jet micromachining of chemically inert and passivating material

Flow field simulation and experimental investigation on macro electrolyte jet electrochemical turning of TB6 titanium alloy

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