Micro Machining of Different Steels with Closed Electrolytic Free Jet

Hackert-Oschätzchen, Matthias; Meichsner, Gunnar; Zeidler, Henning; Zinecker, Mike; Schubert, Andreas

doi:10.1063/1.3589702

Cited by 10 publications

(13 citation statements)

References 3 publications

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“…By a simplification assuming that z = const. , V sp represents a material constant, which is calculated according to Equation (4) [21]. Vsp=Mρ·z·normalF…”

Section: Methodsmentioning

confidence: 99%

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

et al. 2019

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Jet electrochemical machining (Jet-ECM) is a flexible method for machining complex microstructures in high-strength and hard-to-machine materials. Contrary to mechanical machining, in Jet-ECM there is no mechanical contact between tool and workpiece. This enables Jet-ECM, like other electrochemical machining processes, to realize surface layers free of mechanical residual stresses, cracks, and thermal distortions. Besides, it causes no burrs and offers long tool life. This paper presents selected features of Jet-ECM, with special focus on the analysis of the current density during the machining of single grooves in stainless steel EN 1.4301. Especially, the development of the current density resulting from machining grooves intersecting previous machining steps was monitored in order to derive systematic influences. The resulting removal geometry is analyzed by measuring the depth and the roughness of the machined grooves. The correlation between the measured product features and the monitored current density is investigated. This correlation shows that grooves with the desired depth and surface roughness can be machined by controlling current density through the adjustment of process parameters. On the other hand, current density is sensitive to the changes of working gap. As a consequence of the changes of workpiece form and size for the grooves intersecting premachined grooves as well as the grooves with a lateral gap, working gap, and current density change. By analyzing monitoring data and removal geometry results, the suitability of current density inline monitoring to enable process control is shown, especially with regards to manufacture products that should comply with tight predefined specifications.

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“…By a simplification assuming that z = const. , V sp represents a material constant, which is calculated according to Equation (4) [21]. Vsp=Mρ·z·normalF…”

Section: Methodsmentioning

confidence: 99%

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

et al. 2019

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“…An important parameter which affects the cavity widths and depths is nozzle speed. Figure 9(c) shows the variation of cavity depths with nozzle speed [66]. It can be observed that the cavity depths are higher at lower nozzle speeds due to increase in specific dissolution volume.…”

Section: Accepted Manuscriptmentioning

confidence: 96%

A review on process capabilities of electrochemical micromachining and its hybrid variants

Saxena

Qian

Reynaerts

2018

International Journal of Machine Tools and Manufacture

193

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Electrochemical micromachining (micro-ECM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, micro-cavities, microchannels and grooves on conductive and difficult-to-cut materials. Both academia and industry have the consensus that it offers promising machining performance especially in terms of high surface finish, no tool wear and absence of thermally induced defects. Furthermore in order to machine novel materials with extreme properties, novel hybrid electrochemical micromachining technologies are under development. With these hybrid micro-ECM technologies, capabilities of micro-ECM can be expanded by combining it with other processes. To fully exploit the potential as well as improve micro-ECM technology and related hybrid processes, a wide spectrum of multidisciplinary knowledge is needed. The present review systematically discusses process capabilities and research developments of electrochemical micromachining and its hybrid variants considering knowledge of both basic and applied research fields. After few introductory review articles in prior state of the art, this review fills an important gap in research literature by presenting first time an extended literature source with a wide coverage of recent research developments in electrochemical micromachining technology and its hybrid variants. This paper outlines the research and engineering developments in electrochemical micromachining technology and its hybrid variants, review of the related concepts, aspects of tooling, advanced process capabilities and process energy sources. It also provides new sights into technological understanding of micro-ECM technology which will be helpful in future engineering developments of this technology.

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“…EJP in subtractive mode has been successfully applied in creating meso-and micro-scale surface structures across a wide range of materials [15][16][17][18][19][20][21] and applications [22][23][24][25][26]. Prior research work has been carried out to enhance EJP through modification to the nozzle tip [13], enabling modulation of the machined profile, which is distinct from that resulting due to the Gaussian energy distribution ( Fig.…”

Section: Introductionmentioning

confidence: 99%

Transitory electrochemical masking for precision jet processing techniques

Mitchell-Smith

Speidel

Clare

2018

Journal of Manufacturing Processes

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a b s t r a c tElectrochemical jet processing techniques provide an efficient method for large area surface structuring and micro-milling, where the metallurgy of the near-surface is assured and not adversely affected by thermal loading. Here, doped electrolytes are specifically developed for jet techniques to exploit the Gaussian energy distribution as found in energy beam processes. This allows up to 26% reduction in dissolution kerf and enhancements of the defined precision metric of up to 284% when compared to standard electrolytes. This is achieved through the filtering of low energy at discrete points within the energy distribution curve. Two fundamental mechanisms of current filtering and refresh rate are proposed and investigated in order to underpin the performance enhancements found using this methodology. This study aims to demonstrate that a step change in process fidelity and flexibility can be achieved through optimisation of the electrochemistry specific to jet processes.

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Micro Machining of Different Steels with Closed Electrolytic Free Jet

Cited by 10 publications

References 3 publications

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

A review on process capabilities of electrochemical micromachining and its hybrid variants

Transitory electrochemical masking for precision jet processing techniques

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