Experimental investigation of the effects of dedicated electrochemical machining parameters on freeform surface machining

Demirtas, Hasan; Yilmaz, Oğuzhan; Kanber, Bahattin

doi:10.1016/j.jmapro.2019.05.030

Cited by 11 publications

(3 citation statements)

References 18 publications

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“…recast layer by the hybrid process [19]. In addition, some scholars have proposed various algorithms for optimizing process parameters to improve the accuracy of predicting processing results, which helps to shorten the cycle of optimizing process parameters and save manufacturing costs [20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Tang

Yang

Shi

et al. 2022

Int J Adv Manuf Technol

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In order to solve the problems of uneven gap distribution and flow pattern in complex parts with multi-stage internal cone holes in electrochemical machining, a method of computer simulation assisted cathode design was proposed. The electric field and flow field models of machining gaps were established respectively, and the simulation of different cathode profiles was carried out. When the cathode cone angle is 2°, the electric field distribution between the cathode and the workpiece is reasonable, and the electrolyte distribution in the machining gap is uniform. With the conditions of processing voltage 10 V, electrolyte inlet pressure 1.5 MPa, electrolyte temperature 28 ℃ and cathode feed speed 5mm/min, the ECM processing of multi-stage internal cone hole was carried out by using the optimized cathode. The results show that the surface of the workpiece has no flow pattern, the dimensional forming accuracy is better than 0.1mm, and the surface roughness reaches Ra0.697μm.Research shows that the optimization of cathode structure with computer simulation can shorten the cathode development cycle and reduce the cost of cathode design effectively in ECM, which provides an efficient and feasible method for the optimization of complex cathode structure.

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Section: Introductionmentioning

confidence: 99%

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Tang

Yang

Shi

et al. 2022

Int J Adv Manuf Technol

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“…When ECM process is functional in the machining dimensions of 1-999 μm is called Electrochemical micromachining process and it is considered as an advancement of ECM process in the production of micro-scale features [9]. ECMM is one among the different and advanced micromachining technologies considered as the phenomenon of the conventional ECM system on a micro-scale [10].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of 3D surface roughness in electrochemical micromachining of Nitinol

Mouliprasanth¹,

Hariharan²

2021

Surf. Topogr.: Metrol. Prop.

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Equiatomic nickel-titanium (NiTi) composed of Nickel and Titanium (i.e. 50:50% of Ni and Ti) or Nitinol, an expensive, very smart shape memory alloy material of choice for biomedical applications because of its bio compatibility. Machining Nitinol is challenging by means of non-traditional techniques. Experiments are carried out to produce a precise geometrical micro hole in Shape memory alloy Nitinol, using Electrochemical Micromachining (Abbreviated as ECMM). In ECMM process, micro holes are produced with 500 μm tool electrode in a shape memory alloy (SMA)-Nitinol of 0.25 mm thickness using the Non-passivating electrolyte (NPE), Passivating electrolyte (PE) and the Composite electrolyte (CPE) to study the machining characteristics. A tedious effort is made to produce such a micro hole using a noval mixed electrolyte to improve machining process. Polarization studies are also carried out for all the chosen electrolytes. The process is clearly analyzed thoroughly with the help of polarization and SEM. Expected results with good precision and surface characteristics are obtained when the nitinol is machined with the composite electrolyte. The results proved that the compatibility of machining nitinol is composite type of electrolyte. Composite electrolyte provides the combined advantages of both the passivated and non-passivated electrolytes. This study resulted in finding the suitable and optimized parameters for machining Nitinol with PE, NPE and CPE with better precision and good surface integrity.

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“…However, there is no physical contact between the tool and the workpiece during ECM. 20 The electrochemical dissolution effect brings many advantages (e.g. a faster rate of machining of materials irrespective of their hardness, a residual stress-free machined surface, the absence of a heat-affected zone on the machined surface, the elimination of tool wear, a desirable surface finish, and good dimension control and accuracy).…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB₂in situ composites using the Entropy–VIKOR method

Chandrasekhar

Prasad

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article describes the multi-response optimization of electrochemical machining operating parameters such as voltage, concentration of the electrolyte, and current to maximize the rate of material removal in addition to minimize the over cut and delamination at the same time in micro-drilling of AA6061-TiB2 in situ composite. A novel Entropy–VIKOR method is applied to handle such mutually conflicting responses. The weight of each response is computed from the entropy method, and VIKOR method is used to rank the various levels of parameters. This method yields the combination of 2 mol of electrolyte concentration, 16 V of applied voltage, and 4 A of current as optimal parameters to minimize the over cut and delamination in addition to maximize the rate of material removal at the same time. This optimal process-governing parameters satisfied the conditions for compromising solution such as acceptable advantage and acceptable stability condition. The response graph illustrates that, of the parameters investigated, electrolyte concentration has the greatest effect on the VIKOR index, followed by applied voltage and current. Scanning electron microscopic analysis illustrates that the radius of the hole is equal throughout the periphery, except for one instance of micro-delamination.

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Experimental investigation of the effects of dedicated electrochemical machining parameters on freeform surface machining

Cited by 11 publications

References 18 publications

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Evaluation of 3D surface roughness in electrochemical micromachining of Nitinol

Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB₂in situ composites using the Entropy–VIKOR method

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Experimental investigation of the effects of dedicated electrochemical machining parameters on freeform surface machining

Cited by 11 publications

References 18 publications

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

Evaluation of 3D surface roughness in electrochemical micromachining of Nitinol

Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB2in situ composites using the Entropy–VIKOR method

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Product

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Multi-response optimization of electrochemical machining parameters in the micro-drilling of AA6061-TiB₂in situ composites using the Entropy–VIKOR method