Study on wire electrochemical machining assisted with large-amplitude vibrations of ribbed wire electrodes

Fang, Xiaolong; Zou, Xianghe; Chen, M.; Zhu, Daiyin

doi:10.1016/j.cirp.2017.04.135

Cited by 35 publications

(12 citation statements)

References 8 publications

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“…Zhang et al [22] noted that using a double-hole tube electrode can yield cooling holes with a high material removal rate (MRR) and precision as well as a small taper hole in case of high-speed electrochemical discharge drilling. Fang et al [23] studied electrochemical machining in case of the vibrations of a ribbed wire electrode at a large amplitude, and verified that this enhanced the electrolyte renewal of and bubble removal from the electrode. To better remove products from the gap and thus improve the accuracy and efficiency of machining, Zou et al [24] proposed wire electrochemical micro-machining using a cutting edge tool electrode.…”

Section: Introductionmentioning

confidence: 97%

Performance improvement of high-speed EDM and ECM combined process by using a helical tube electrode with matched internal and external flushing

Zhang

Wang

et al. 2021

Int J Adv Manuf Technol

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Micro-hole fabrication at a high speed and accuracy of machining while maintaining high surface quality is challenging. A core difficulty is the removal of the products of machining from extremely narrow gaps. To solve this problem, this study proposes an approach that combines high-speed electrical discharge machining (EDM) with electrochemical machining (ECM) by using a helical tube electrode with matched internal and external flushing. During high-speed electrical discharge drilling, matching the internal flushing with the clockwise rotation of the helical electrode can help remove debris from the bottom of the blind hole. During ECM, matching the external flushing with the anticlockwise rotation of the helical electrode can improve the flow of electrolyte in the gap. First, the flow field was simulated to show that matching the internal and external flushing of the helical electrode can enhance the flow of the medium and reduce particle concentration in extremely narrow gaps. Second, a series of experiments were conducted to verify that the taper of the hole and the surface quality of its wall can be improved by using the helical tube electrode. Finally, an experiment was carried out to optimize the machining parameters, and yielded a minimum taper of 0.008 at a speed of rotation of 460 rpm, and pressures of internal and external flushing of 9 MPa and 4 MPa, respectively.

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Section: Introductionmentioning

confidence: 97%

Performance improvement of high-speed EDM and ECM combined process by using a helical tube electrode with matched internal and external flushing

Zhang

Wang

et al. 2021

Int J Adv Manuf Technol

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“…Slits with a length of 10 mm and an average width of 0.903 mm were machined with a feed rate of 6 µm/s in a 30-mm-thick block. Vibration is also a widely used auxiliary method: Fang et al [ 13 ] adopt a ribbed wire electrode with large amplitude vibration to enhance electrolyte renewal and bubble removal in WECMM, and a fir-tree-like turbine-disk tenon with a machined surface roughness of R a = 0.682 μm was fabricated on a plate of 5 mm in thickness. The applied vibration amplitude was 7.5 mm and the frequency was 1.5 Hz.…”

Section: Introductionmentioning

confidence: 99%

Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

Ling

Liu

et al. 2020

Micromachines

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Wire electrochemical micromachining (WECMM) technology is regarded a promising method to fabricate high aspect ratio microstructures on hard-to-machining materials, however, the by-product accumulation in the machining gap limits its application. In this paper, a new method called ultrasonic-assisted wire electrochemical micromachining (UA-WECMM) is proposed to improve the machining performance of WECMM. Firstly, a flow-field simulation in the machining gap was carried out; the results showed that the ultrasonic vibration of electrode can remarkably enhance the mass transport in the machining gap and improve the machining condition. Secondly, experiments were performed to confirm the effect of ultrasonic vibration, which illustrated that the vibration with proper amplitude can reduce the slit width and improve the morphology of machined surface. Moreover, the influence of other machining parameters were also discussed. Finally, a T-type micro connector with good surface roughness (Ra 0.286 μm) was fabricated on a 300-μm-thick 304 stainless steel workpiece and a micro gear (diameter: 3.362 mm; Ra: 0.271 μm) with an aspect ratio of 7 was fabricated on a 2-mm-thick workpiece. It is proved that the proposed ultrasonic-assisted wire electrochemical micromachining method has considerable potential and broad application prospects.

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“…Under the same optimized machining parameters, the machined surface roughness decreased from 0.245 to 0.168 µm [ 23 ]. Fang et al verified that vibration effectively promotes the discharge of bubbles by high-speed video camera, thereby improving machining efficiency and machining quality [ 24 , 25 , 26 , 27 ]. Goel and Pandey studied the effects of various machining parameters on material removal rate and hole taper in electrode ultrasonic vibration-assisted micro electrochemical drilling.…”

Section: Introductionmentioning

confidence: 99%

Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

Liu

Chen

Wang

et al. 2020

Sensors

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With the rapid development of MEMS, the demand for metal microstructure is increasing. Micro electrochemical milling technology (MECM) is capable of manufacturing micro metallic devices or components based on the principle of electrochemical anode dissolution. To improve the capacity of MECM, this paper presents a compound method named ultrasonic vibration-assisted micro electrochemical milling technology (UA-MECM). Firstly, the simulation and mathematical model of UA-MECM process is established to explain the mechanism of ultrasonic vibration on micro electrochemical milling. Then, the effects of ultrasonic parameters, electrical parameters and feedrate on machining localization and surface quality are discussed considering sets of experiments. The surface roughness was effectively reduced from Ra 0.83 to Ra 0.26 µm with the addition of ultrasonic vibration. It turns out that ultrasonic vibration can obviously improve machining precision, efficiency and quality. Finally, two- and three-dimensional microstructures with good surface quality were successful fabricated. It shows that ultrasonic vibration-assisted electrochemical milling technology has excellent machining performance, which has potential and broad industrial application prospects.

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Study on wire electrochemical machining assisted with large-amplitude vibrations of ribbed wire electrodes

Cited by 35 publications

References 8 publications

Performance improvement of high-speed EDM and ECM combined process by using a helical tube electrode with matched internal and external flushing

Performance improvement of high-speed EDM and ECM combined process by using a helical tube electrode with matched internal and external flushing

Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

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