Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

Liu, Yong; Chen, Haoran; Wang, Shenghai; Wang, Kan; Li, Minghao; Peng, Tengfei

doi:10.3390/s20226617

Cited by 9 publications

(4 citation statements)

References 32 publications

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“…Mitchell-Smith et al produced different groove geometries by optimizing the bottom structure of a metallic nozzle to change current density distribution [ 10 ]. Liu et al proposed a method of ultrasonic vibration-assisted electrochemical milling, which was helpful to improve the machined surface quality, and a three-dimensional structure with the total depth of 300 μm was machined [ 11 ]. Liu and Qu analyzed the anodic polarization curves of TB6 in NaNO 3 solution and the effect of current density on the morphology, and grooves and flat surfaces were machined successfully by electrochemical milling [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Electrochemical Milling of Deep-Narrow Grooves on GH4169 Alloy Using Tube Electrode with Wedged End Face

Qiu

Chen

2022

Micromachines

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Deep-narrow grooves (DNGs) of nickel-based alloy GH4169 are extensively used in aerospace industry. Electrochemical milling (EC-milling) can manufacture special structures including DNGs by controlling the moving path of simple tool, showing a flexible process with the advantages of high machining efficiency, regardless of material hardness, no residual stresses, burrs, and tool wear. However, due to the inefficient removal of electrolytic by-products in the inter-electrode gap (IEG), the machining accuracy and surface quality are always unsatisfactory. In this paper, a novel tube tool with wedged end face is designed to generate pulsating flow field in IEG, which can enhance the removal of electrolytic by-products as well as improve the machining quality of DNG. The flow field simulation results show that the electrolyte velocity in the IEG is changed periodically along with the rotation of the tube tool. The pulsating amplitude of electrolyte is changed by adjusting the wedged angle in the end face of the tube tool, which could affect the EC-milling process. Experimental results suggest that the machining quality of DNG, including the average width, taper of sidewall, and surface roughness, is significantly improved by using the tube tool with wedged end face. Compared with other wedged angles, the end face with the wedged angle of 40° is more suitable for the EC-milling process. DNG with the width of 1.49 mm ± 0.04 mm, taper of 1.53° ± 0.46°, and surface roughness (Ra) of 1.04 μm is well manufactured with the milling rate of 0.42 mm/min. Moreover, increasing the spindle speed and feed rate can further improve the machining quality of DNG. Finally, a complex DNG structure with the depth of 5 mm is well manufactured with the spindle speed of 4000 rpm and feed rate of 0.48 mm/min.

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Section: Introductionmentioning

confidence: 99%

Electrochemical Milling of Deep-Narrow Grooves on GH4169 Alloy Using Tube Electrode with Wedged End Face

Qiu

Chen

2022

Micromachines

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“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 µm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [5]; (2) analysis and modification of electric current distribution on the workpiece surface [6,7]; (3) selection of optimal composition of electrolyte [8]; (4) technology development, i.e., simulation of machining or the tool shape/path design [9];…”

Section: Introductionmentioning

confidence: 99%

“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 μm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [ 5 ]; (2) analysis and modification of electric current distribution on the workpiece surface [ 6 , 7 ]; (3) selection of optimal composition of electrolyte [ 8 ]; (4) technology development, i.e., simulation of machining or the tool shape/path design [ 9 ]; (5) development of power suppliers and gap control strategy [ 10 ]; and (6) improvement of machining conditions by additional energy sources (i.e., ultrasonic vibrations [ 11 , 12 ]) or (7) integration with other technologies [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Selected Aspects of Electrochemical Micromachining Technology Development

et al. 2021

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The paper focuses on the fundamentals of electrochemical machining technology de-elopement with special attention to applications for micromachining. In this method, a material is removed during an anodic electrochemical dissolution. The method has a number of features which make it attractive technology for shaping parts with geometrical features in range of micrometres. The paper is divided into two parts. The first one covers discussion on: general characteristics of electrochemical machining, phenomena in the gap, problems resulting from scaling down the process and electrochemical micromachining processes and variants. The second part consists of synthetic overview of the authors’ research on localization of pulse electrochemical micromachining process and case studies connected with application of this method with use of universal cylindrical electrode-tool for shaping cavities in 1.4301 stainless steel. The latter application was conducted in two following variants: electrochemical contour milling and shaping carried out with sidewall surface of rotating tool. In both cases, the obtained shape is a function of electrode tool trajectory. Selection of adequate machining strategy allows to obtain desired shape and quality.

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“…29 For electrochemical milling, Liu et al used rotating helical flat electrodes assisted by ultrasound to reduce the surface roughness from Ra 0.83 μm to Ra 0.26 μm. 30 Wu et al added B 4 C particles to the electrolyte to achieve the polishing effect by high-frequency cathode vibration. 31 To intensify the effect produced by vibration, the electrode structure is usually redesigned with discs, threads, ribbing, and other shapes.…”

mentioning

confidence: 99%

Ultrasonic-Assisted Electrochemical Milling of SLM-Printed Hastelloy X Based on Analysis of Material Passivation Characteristics

Guan¹,

Liu²,

Shu³

et al. 2022

J. Electrochem. Soc.

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Hastelloy X (HX) is widely used in the aerospace field for its excellent corrosion resistance and high-temperature mechanical properties that can be fabricated into complex structures directly via the selective laser melting (SLM) technique. However, SLM-printed (SLM-ed) HX with high strength and hardness is challenging to process using conventional manufacturing techniques and may result in machining flaws that do not fulfill engineering standards. Therefore, an ultrasonic-assisted electrochemical milling (UAECM) method using a tube electrode is proposed to fabricate high aspect ratio structures on SLM-ed HX with high-quality. First, the passivation characteristics of SLM-ed HX before and after solid solution treatment were investigated using polarization curves and electrochemical impedance spectroscopy. The electrochemical milling process and the electrode gap flow field were then simulated andthe effect of processing parameters such as ultrasonic amplitude, electrical parameters, and mechanical parameters on the groove width and stability was investigated by torthogonal and single factor experiments. Finally, the cavity and bump structures were machined by layered milling with an average groove width of 960±15µm, a groove depth of 4.4 mm, an aspect ratio of 4.5, and surface roughness of 1.524 and 1.622 µm, respectively, demonstrating the adaptability and machining accuracy of the UAECM method.

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Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

Cited by 9 publications

References 32 publications

Electrochemical Milling of Deep-Narrow Grooves on GH4169 Alloy Using Tube Electrode with Wedged End Face

Electrochemical Milling of Deep-Narrow Grooves on GH4169 Alloy Using Tube Electrode with Wedged End Face

Selected Aspects of Electrochemical Micromachining Technology Development

Ultrasonic-Assisted Electrochemical Milling of SLM-Printed Hastelloy X Based on Analysis of Material Passivation Characteristics

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