Experimental investigation of micro wire electrochemical discharge machining by using a rotating helical tool

Liu, Yong; Wei, Zhiyuan; Wang, Mingyu; Zhang, Jianhua

doi:10.1016/j.jmapro.2017.08.004

Cited by 40 publications

(16 citation statements)

References 20 publications

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“…According to the previous research literature [19][20][21][22], the tungsten carbide electrode was selected. According to the research of Fang et al [23], in wire electrochemical discharge machining (WECDM), when a spiral electrode was used, the axial updating speed of electrolyte was accelerated, and the uniformity of the slit width in the depth direction was enhanced.…”

Section: Methodsmentioning

confidence: 99%

“…According to the research of Fang et al [23], in wire electrochemical discharge machining (WECDM), when a spiral electrode was used, the axial updating speed of electrolyte was accelerated, and the uniformity of the slit width in the depth direction was enhanced. Liu studied the machining locality of the spiral electrode in the WECDM process, and fabricated a series of kerfs with 138 µm wide [19]. For this reason, the spiral electrode was selected.…”

Section: Methodsmentioning

confidence: 99%

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Experimental Study of Tool Wear in Electrochemical Discharge Machining

Bian

Liu

et al. 2020

Applied Sciences

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Electrochemical discharge machining (ECDM) is an emerging special processing technology for non-conductive hard and brittle materials, but it may encounter the problem of tool wear due to its process characteristics, which affects the processing accuracy. In this study, in the non-machining state, the tungsten carbide spiral cathode with a diameter of 400 μm was selected to analyze the influencing mechanism of the process parameters on tool wear, and a suitable voltage range for the processing was obtained. The influence of the cathode’s loss behavior on the film formation time and the average current of spark discharge was discussed based on the current signal. The results show that the tool wear mainly appears from the bottom to the end and edge tip of the protrusion. Loss is mainly in the form of local material melting or gasification at high temperature. In addition, the loss may shorten the film formation time, but the effect on the average current of spark discharge is small.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Experimental Study of Tool Wear in Electrochemical Discharge Machining

Bian

Liu

et al. 2020

Applied Sciences

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“…From Figure 14(c), it was observed that HOC reduced with increased tool rotation speed. Liu et al 38 identified the reason of reduction in HOC. They have found that stable gas bubble creation is difficult in high tool rotation speed and unstable gas bubbles deteriorate discharge conditions.…”

Section: Comparison Of Top and Inside Machining For Hocmentioning

confidence: 99%

A novel approach for removal of delaminated fibers of a reinforced composites using electrochemical discharge machining

Harugade

Waigaonkar

Dhawale³

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Fiber reinforced composites, also referred as fiber reinforced plastics (FRPs) have gained considerable importance in engineering applications due to their unique qualities like high strength and stiffness at lesser weight, chemical inertness, thermal resistance, corrosion resistance, and electrical resistance. Though the machining of FRPs is not recommended, many times it is inevitable and the primary machining process like drilling is essential. This can cause delamination of the fibers thereby adversely affecting the mechanical properties of the composite and requires additional secondary finishing operation. The present investigation explores electrochemical discharge machining (ECDM) as a one of the novel technique to remove the delaminated fibers from such composites. Using ECDM the protruded delaminated fibers from a drilled hole in FRP have been precisely eliminated. Two different approaches viz. top machining and inside machining were followed for this purpose. Process evaluation was done in terms of its ability to remove the delaminated fibers and the extent of thermal damage (heat affected zone and hole overcut) to the workpiece. Both approaches have shown considerable potential of removal of delaminated fibers precisely.

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“…Even though it is challenging to fabricate these structures in thick substrates, details such as the number of machined layers, machining time, and the etch depth of each layer are not provided. Difficulties involved in the fabrication of helical tools and tool rotation requirements limit using the method proposed in Liu et al 29,30 Mishra et al 31 have reported on the realization of high aspect ratio microchannels with depths greater than 1100 mm using a multi-pass micro-milling technique. A through channel of depth ;1100 mm was realized on the 16th pass on a glass substrate while using a 30 wt.% KOH electrolytic solution, a relatively high DC pulsed supply of 60 V, and steel rods as the cathode.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of micro-mechanical planar cantilever beam-mass structures on quartz substrates using an ECDM process

Sambathkumar

Sankar

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrochemical discharge machining (ECDM) processes have been used to realize miniature structures such as micro-channels and micro-holes on non-conductive materials such as quartz and Pyrex for a variety of applications. However, for realizing mechanical/physical sensors, actuators, energy harvesters, and resonators on glass substrates, free-standing devices with movable components such as beam-mass structures and cantilevers are required. There has been a negligible focus on developing miniature glass-based devices with movable components primarily due to the non-linear material removal rate (MRR) of the ECDM processes, requiring continuous measurement, tracking, and maintaining the working gap in the range of a few micrometers during micromachining. A couple of techniques were proposed to address maintaining a constant working gap, however, using costly equipment with complex feedback mechanisms. We report a two-stage experimental approach – without using feedback mechanisms and additional equipment – to realize micro-mechanical planar cantilever beam-mass structures on thick quartz substrates in the present work. In the first stage, the process parameters such as applied voltage, tool travel rate (TTR), and initial working gap ( Wg) are optimized for fabricating broader and deeper micro-channels using needle-shaped tools. In the second stage, using the optimized parameters, an array of micro-channels is fabricated. The cumulative depth, corresponding depth, and the width of each layer of the channels are measured, and this data is utilized for fabricating planar beam-mass structures on quartz substrates. We envisage that the experimental results of the present study would be beneficial for ECDM researchers to fabricate glass-based miniature devices with movable components without using complex tools and equipment.

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Experimental investigation of micro wire electrochemical discharge machining by using a rotating helical tool

Cited by 40 publications

References 20 publications

Experimental Study of Tool Wear in Electrochemical Discharge Machining

Experimental Study of Tool Wear in Electrochemical Discharge Machining

A novel approach for removal of delaminated fibers of a reinforced composites using electrochemical discharge machining

Fabrication of micro-mechanical planar cantilever beam-mass structures on quartz substrates using an ECDM process

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