Influences of gap pressure on machining performance in radial ultrasonic rolling electrochemical micromachining

Wang, Minghuan; Chen, Xia; Tong, Wenjun; Wang, Jiajie; Wang, Xindi

doi:10.1007/s00170-020-05012-7

Cited by 14 publications

(4 citation statements)

References 25 publications

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“…Pawariya [16] used ultrasonic vibration of tool electrode of ECDM to investigate and enhance deep microholes in difficultto-machine metal materials. Wang [17] reported that tool vibration improves machining the efficiency, surface quality, and gap environment of ECM.…”

Section: Introductionmentioning

confidence: 99%

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Chen

Zhu

2022

Materials

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Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.

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Section: Introductionmentioning

confidence: 99%

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Chen

Zhu

2022

Materials

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“…13 To enhance the machining accuracy of radial ultrasonic rolling micromachining, a set of suitable gap pressure parameters was optimized. 14 By using a pulsating electrolyte, the surface quality of the workpiece was improved. 15 In straight bevel gear finishing, the differences of performance between pulsed-electrochemical honing and finishing were compared.…”

Section: Introductionmentioning

confidence: 99%

Electrochemical trepanning of blades made of Inconel 625

Lei

Zhu

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the aerospace field, difficult-to-machine materials are used widely to improve engine performance. As a nickel-based material that performs well in all aspects, Inconel 625 is used for the blisks of aircraft engines, and electrochemical trepanning (ECTr) is used widely to fabricate such blisks because of its unique advantages regarding ruled surface parts. In this study, to investigate the performance of Inconel 625 in ECTr, measurements were made of the electrochemical characteristics firstly, specifically the anodic polarization curve and the actual volumetric electrochemical equivalent curve. Then, via dynamic electric-field simulations, the processes for forming Inconel 625 blades using ECTr were examined under direct voltage (DV) and pulsed voltage. The contours and current density distributions of formed blades at different times were obtained under different duty cycles. With decreasing duty cycle, the forming accuracy improved gradually and the stray current was reduced. To verify the simulation results, ECTr experiments with Inconel 625 were performed under different voltage conditions. With DV and 90% and 80% duty cycle, the taper angles of the machined blades were 7.784°, 6.278°, and 5.191°, respectively, and the surface roughness ( Ra) values were 0.95, 0.81, and 0.72 μm, respectively. With DV, there were obvious flow marks and gullies on the microscopic surface. With decreasing duty cycle, stray corrosion was reduced effectively and the state of the flow field was improved. Overall, the simulation results were verified effectively.

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“…The radial ultrasonic rolling electrochemical micromachining (RUR-EMM) combined rolling electrochemical micromachining (R-EMM) and ultrasonic vibration was studied [ 16 ], its machining efficiency and the quality of surface machined are both improved with the combination of their benefits. However, affected by many factors, such as applied voltage, pulse frequency, electrode rotation velocity, and the interelectrode gap, microstructure forming size is relatively difficult to control.…”

Section: Introductionmentioning

confidence: 99%

The Optimal Processing Parameters of Radial Ultrasonic Rolling Electrochemical Micromachining—RSM Approach

Chen

Wang

2020

Micromachines

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Radial ultrasonic rolling electrochemical micromachining (RUR-EMM) is a new method of electrochemical machining (ECM). By feeding small and rotating electrodes aided by ultrasonic rolling, an array of pits can be manufactured, which is called microstructures. However, there still exists the problem of choosing the optimal machining parameters to realize the workpiece machining with high quality and high efficiency. In the present study, response surface methodology (RSM) was proposed to optimize the machining parameters. Firstly, the performance criteria of the RUR-EMM are measured through investigating the effect of working parameters, such as applied voltage, electrode rotation speed, pulse frequency and interelectrode gap (IEG), on material removal amount (MRA) and surface roughness (Ra). Then, the experimental results are statistically analyzed and modeled through RSM. The regression model adequacies are checked using the analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated and verified by experiment to maximize MRA and minimize Ra. The results show that each parameter has a similar and non-linear influence on the MRA and Ra. Specifically, with the increase of each parameter, MRA increases first and decreases when the parameters reach a certain value. On the contrary, Ra decreases first and then increases. Under the combined effect of these parameters, the productivity is improved. The experimental value of MRA and Ra is 0.06006 mm2 and 51.1 nm, which were 0.8% and 2.4% different from the predicted values.

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Influences of gap pressure on machining performance in radial ultrasonic rolling electrochemical micromachining

Cited by 14 publications

References 25 publications

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Electrochemical trepanning of blades made of Inconel 625

The Optimal Processing Parameters of Radial Ultrasonic Rolling Electrochemical Micromachining—RSM Approach

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