Theoretical and experimental investigation on electrochemical micromachining

Zhang, Zhaoyang; Zhu, Daiyin; Qu, Ningsong; Wang, Minghuan

doi:10.1007/s00542-006-0369-7

Cited by 38 publications

(18 citation statements)

References 9 publications

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“…For the experiments, NaNO mixed with a small amount of HCl was used as electrolyte. HCl was combined with other chemicals in many papers [8,10,14,[50][51][52][53][54][55][56][57][58] in concentrations varying from 0.01M HCl [14] up to 3M HCl [10]. In the following experiments, a mixture of 0.1M H SO and 0.5M NaNO solutions was used as electrolyte.…”

Section: Machining Resultsmentioning

confidence: 99%

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Design of an electrochemical micromachining machine

Spieser

Ivanov

2014

Int J Adv Manuf Technol

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Electrochemical micromachining (µECM) is a nonconventional machining process based on the phenomenon of electrolysis. µECM became an attractive area of research due to the fact that this process does not create any defective layer after machining and that there is a growing demand for better surface integrity on different micro applications including microfluidics systems, stress free drilled holes in automotive and aerospace manufacturing with complex shapes etc.This work presents the design of a next generation µECM machine for the automotive, aerospace, medical and metrology sectors. It has 3 axes of motion (X,Y,Z) and a spindle allowing the tool-electrode to rotate during machining.The linear slides for each axis use air bearings with linear DC brushless motors and 2nm-resolution encoders for ultra precise motion. The control system is based on the Power PMAC motion controller from Delta Tau. The electrolyte tank is located at the rear of the machine and allows the electrolyte to be changed quickly. This machine features two process control algorithms: fuzzy logic control and adaptive feed rate.A self-developed pulse generator has been mounted and interfaced with the machine and a wire ECM grinding device has been added. The pulse generator has the possibility to reverse the pulse polarity for on-line tool fabrication.

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Section: Machining Resultsmentioning

confidence: 99%

“…This new technology can nowadays be applied at a micrometre scale and is called 'Pulse Electrochemical Micromachining' (also referred to as µECM, µPECM, EMM, PECMM, PEMM) [6][7][8][9]. In most papers, the frequency and the pulse duration are respectively much higher and much shorter than in initial PECM [10,11].…”

Section: Fundamentalsmentioning

confidence: 99%

Design of an electrochemical micromachining machine

Spieser

Ivanov

2014

Int J Adv Manuf Technol

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“…In µECM drilling and milling operations, the tool-electrode can be fabricated online by electrochemical etching [4,[10][11][12][13][14] or in a manner similar to the Wire Electro-Discharge Grinding devices which allows to achieve very small sizes [15,16]. Figure 2 shows an example of a micro tool electrode being machined using electrochemical etching (with a DC voltage) followed by the machining of the workpiece (with a pulsed voltage).…”

Section: On-the-machine Tool Etchingmentioning

confidence: 99%

“…The dissolution process can be accurately confined by setting the pulse duration according to the charging time of the EDL [2][3][4][5][6]. The frequency and the pulse duration are respectively higher and shorter than in initial PECM [7,8].…”

Section: Introductionmentioning

confidence: 99%

Design of a pulse power supply unit for micro-ECM

Spieser

Ivanov

2014

Int J Adv Manuf Technol

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Electrochemical micromachining (µECM) requires a particular pulse power supply unit (PSU) to be developed in order to achieve desired machining performance. This paper summarizes the development of a pulse PSU meeting the requirements of µECM. The pulse power supply provides tens of nanosecond pulse duration, positive and negative bias voltages, and a polarity switching functionality. It fulfils the needs for tool preparation with reversed pulsed ECM on the machine. Moreover, the PSU is equipped with an ultrafast over current protection which prevents the toolelectrode from being damaged in case of short-circuits.The developed pulse PSU was used to fabricate micro tools out of 170µm WC-Co alloy shafts via micro electrochemical turning and drill deep holes via µECM in a disk made of 18NiCr6. The electrolyte used for both processes was a mixture of sulphuric acid and NaNO3 aqueous solutions.

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“…When a working mechanism of ECM is utilized in the micro domain for micro range applications, it is called electrochemical micromachining (EMM) [1]. Recently, much development in EMM has taken place which proves that ECM is a viable technology for the micromachining domain [2]. EMM emerged as highly capable micromachining technology because of its advantages such as high material removal rate (MRR), improved precision and control, reliability, flexibility, and environment friendly [3].…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation into fabrication of microfeatures on titanium by electrochemical micromachining

Anasane

Bhattacharyya

2016

Adv. Manuf.

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Titanium machining is one of the challenging tasks to modern machining processes. Especially fabricating microfeatures on titanium appear as a potential research interest. Electrochemical micromachining (EMM) is an effective process to generate microfeatures by anodic dissolution. Machining of titanium by anodic dissolution is different than other metals because of its tendency to form passive oxide layer. The phenomenon of progression of microfeature by conversion of passive oxide layer into transpassive has been investigated with the help of maskless EMM technique. Suitable range of machining voltage has been established to attain the controlled anodic dissolution of titanium by converting passive oxide film of titanium into transpassive with nonaqueous electrolyte. The experimental outcomes revealed that the micromachining of titanium with controlled anodic dissolution could be possible even at lower machining voltage in the range of 6-8 V. This work successfully explored the possibility of generation of microfeatures on commercially pure titanium by anodic dissolution process in microscopic domain by demonstrating successful fabrication of various microfeatures, such as microholes and microcantilevers.

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Theoretical and experimental investigation on electrochemical micromachining

Cited by 38 publications

References 9 publications

Design of an electrochemical micromachining machine

Design of an electrochemical micromachining machine

Design of a pulse power supply unit for micro-ECM

Experimental investigation into fabrication of microfeatures on titanium by electrochemical micromachining

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