Wire electrochemical micromachining of high-quality pure-nickel microstructures focusing on different machining indicators

Bi, Xiaolei; Zeng, Yongbin; Qu, Ningsong

doi:10.1016/j.precisioneng.2019.09.015

Cited by 7 publications

(3 citation statements)

References 23 publications

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“…Therefore, WECMM is an ideal technique to manufacture three-dimensional microstructures from pure aluminum. WECMM has been successful for fabricating high-quality three-dimensional microstructures from a wide range of materials, such as pure nickel [ 11 ], stainless steel [ 12 ], cobalt-based alloys [ 13 ], and zr-based amorphous alloys [ 14 ]. Recently, high-quality three-dimensional micromachining of pure aluminum has been achieved through WECMM, but this is possible only in short-duration WECMM [ 2 ].…”

Section: Introductionmentioning

confidence: 99%

Micro-Shaping of Pure Aluminum in Long-Duration Wire Electrochemical Micromachining Using Bipolar Nanosecond Pulses

Jia

Meng

2023

Micromachines

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With the increasing application of three-dimensional pure aluminum microstructures in micro-electromechanical systems (MEMS) and for fabricating terahertz components, high-quality micro-shaping of pure aluminum has gradually attracted attention. Recently, high-quality three-dimensional microstructures of pure aluminum with a short machining path have been obtained through wire electrochemical micromachining (WECMM), owing to its sub-micrometer-scale machining precision. However, machining accuracy and stability decrease owing to the adhesion of insoluble products on the surface of the wire electrode in long-duration WECMM, which limits the application of pure aluminum microstructures with a long machining path. In this study, the bipolar nanosecond pulses are used to improve the machining accuracy and stability in long-duration WECMM of pure aluminum. A negative voltage of −0.5 V was considered appropriate based on experimental results. Compared with the traditional WECMM using unipolar pulses, the machining accuracy of the machined micro-slit and the duration of stable machining were significantly improved in long-duration WECMM using bipolar nanosecond pulses.

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Section: Introductionmentioning

confidence: 99%

Micro-Shaping of Pure Aluminum in Long-Duration Wire Electrochemical Micromachining Using Bipolar Nanosecond Pulses

Jia

Meng

2023

Micromachines

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“…ECM is an efficient and low-cost machining method for Ni-based alloys [2]. Several works were carried out to study the machinability of Ni alloys by ECM [3][4][5]. Ni alloys are primarily used in aircrafts, power generation turbines, rocket engines, chemical processing plants, and nuclear power plants.…”

Section: Introductionmentioning

confidence: 99%

Meta-Heuristic Technique-Based Parametric Optimization for Electrochemical Machining of Monel 400 Alloys to Investigate the Material Removal Rate and the Sludge

Nagarajan¹,

Ayyappan²,

Kumar

et al. 2022

Applied Sciences

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Electrochemical machining (ECM) is a preferred advanced machining process for machining Monel 400 alloys. During the machining, the toxic nickel hydroxides in the sludge are formed. Therefore, it becomes necessary to determine the optimum ECM process parameters that minimize the nickel presence (NP) emission in the sludge while maximizing the material removal rate (MRR). In this investigation, the predominant ECM process parameters, such as the applied voltage, flow rate, and electrolyte concentration, were controlled to study their effect on the performance measures (i.e., MRR and NP). A meta-heuristic algorithm, the grey wolf optimizer (GWO), was used for the multi-objective optimization of the process parameters for ECM, and its results were compared with the moth-flame optimization (MFO) and particle swarm optimization (PSO) algorithms. It was observed from the surface, main, and interaction plots of this experimentation that all the process variables influenced the objectives significantly. The TOPSIS algorithm was employed to convert multiple objectives into a single objective used in meta-heuristic algorithms. In the convergence plot for the MRR model, the PSO algorithm converged very quickly in 10 iterations, while GWO and MFO took 14 and 64 iterations, respectively. In the case of the NP model, the PSO tool took only 6 iterations to converge, whereas MFO and GWO took 48 and 88 iterations, respectively. However, both MFO and GWO obtained the same solutions of EC = 132.014 g/L, V = 2406 V, and FR = 2.8455 L/min with the best conflicting performances (i.e., MRR = 0.242 g/min and NP = 57.7202 PPM). Hence, it is confirmed that these metaheuristic algorithms of MFO and GWO are more suitable for finding the optimum process parameters for machining Monel 400 alloys with ECM. This work explores a greater scope for the ECM process with better machining performance.

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“…The experimental results showed that the surface roughness of the machined kerf was improved from 1.43 to 0.44 µm by changing the frequency of the voltage pulse from 100 to 200 kHz. Bi et al [20] investigated the fabrication of pure nickel microstructures, concentrating on different types of machining indicators. Based on the experimental result, a rounded edge with high surface quality was obtained by increasing the pulse period and feed rate.…”

Section: Introductionmentioning

confidence: 99%

Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Mahardika

Setyawan

Sriani³

et al. 2021

Machines

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Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

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Wire electrochemical micromachining of high-quality pure-nickel microstructures focusing on different machining indicators

Cited by 7 publications

References 23 publications

Micro-Shaping of Pure Aluminum in Long-Duration Wire Electrochemical Micromachining Using Bipolar Nanosecond Pulses

Micro-Shaping of Pure Aluminum in Long-Duration Wire Electrochemical Micromachining Using Bipolar Nanosecond Pulses

Meta-Heuristic Technique-Based Parametric Optimization for Electrochemical Machining of Monel 400 Alloys to Investigate the Material Removal Rate and the Sludge

Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

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