Fabrication of Micro Structures by Ultra Short Voltage Pulse Electrochemical Machining

2009 ◽  
Vol 419-420 ◽  
pp. 813-816 ◽  
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Wan Sheng Zhao
Keyword(s):  
Voltage Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Stray Current ◽  
Micro Fabrication ◽  
Micro Hole ◽  
Micro Structures ◽  
Machining Localization

. The purpose of this paper is to study the application of electrochemical machining (ECM) technology for the fabrication of micro structures. The stray current corrosion, i.e. machining localization is a critical obstacle to micro fabrication for ECM. To machine micro structures by electrochemical machining ultra short voltage pulse is used. The effects of electrochemical machining parameters such as voltage, pulse duration, pulse frequency, and electrolyte composition on the machining accuracy were studied. In experiments, a micro hole was machined on stainless steel with cylindrical and square electrodes to investigate these effects.

Study and Application on Ultrasonical Combined Electrical Micro-Machining the Special Shape Micro-Structures

2013 ◽  
Vol 313-314 ◽  
pp. 711-716
Author(s):  
Yong Wei Zhu ◽  
Yu Ren Du ◽  
Xing Lei Miao ◽  
Nai Zhang Yun
Keyword(s):  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Micro Machining ◽  
Special Shape ◽  
Friction Units ◽  
Machining System ◽  
Hard And Brittle Materials ◽  
Low Amplitude ◽  
Micro Structures

For manufacturing the special shape micro-structures with hard and brittle materials , the ultrosonical combined electrical micro-machining method is proposed and improved. The ultrasonical combined synchronous electrochemical micro-machining system is built and optimized, which machining parameters can be adjusted in a big ranges, and the synchronous target between the ultrasonical vibration and the voltage of micro-PECM(Micro-pulse electrochemical machining) can be realized. The micro-machining electrodes are manufactured in round sections by combined micro electrical-discharged machining (EDM).The mechanism tests of ultrasonic vibration combined electrical pulse micro-machining tests are carried. It is adopted that the low amplitude of electrical voltage (no more than 6V) and the static electrolyte with lower electrical conduction rate, the good machining accuracy and surface quality are acquired. The regular morphology array micro-round holes are manufactured successfully on friction units' working surface, which can save oil , improve the friction performances and prolonging working life of important friction units. In additional, the fixed holes satisfying the precision needs are machined on the hard and brittle piezo-ceramics pieces, which are often used in many important micro-precise piezo-ceramics sensor. It is proved that ultrasonic combined electrical micro-machining is an effect method for to machine the special shape micro-structures.

Process Experimental Research of Micro-Hole in Electrochemical Micromachining by Nanosecond Pulse Current

2013 ◽  
Vol 764 ◽  
pp. 15-19
Author(s):  
Zhi Yong Li ◽  
Hong Li Liu ◽  
Zhi Peng Duan
Keyword(s):  
Pulse Current ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Anode Dissolution ◽  
Micro Hole ◽  
Processing Accuracy ◽  
Hole Machining

Electrochemical micro-machining (ECMM) is a method that utilizes anode dissolution principle to process shaping. In the Electrochemical machining （ECM）of micro-hole, machining precision is an important aspect to measure machining quality of micro-hole. In this paper micro-hole machining is regarded as the research object, effects of many factors such as power supply natures, electrolyte composition, pulse width and pulse frequency on machining accuracy in micro-hole ECM have been evaluated. Research shows that processing accuracy can be improved through using non-linear electrolyte in high frequency, narrow pulse electrochemical machining.

scholarly journals Research on Stagger Coupling Mode of Pulse Duration and Tool Vibration in Electrochemical Machining

2018 ◽  
Vol 8 (8) ◽  
pp. 1296 ◽  
Author(s):  
Xiaochen Jiang ◽  
Jia Liu ◽  
Di Zhu ◽  
Mingming Wang ◽  
Ningsong Qu
Keyword(s):  
Pulse Duration ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Tool Vibration ◽  
Coupling Mode ◽  
Machining Localization ◽  
Electrolysis Products ◽  
Gas Void Fraction

Tuning the coupling of pulse duration and tool vibration in electrochemical machining (PVECM) is an effective method to improve machining accuracy and surface quality. In general, the pulse is set at the same frequency as the tool vibration, and a symmetrical distribution is attained at the minimum inter-electrode gap. To analyse the characteristics of the electrolyte fluid flow and of the electrolysis products in the oscillating inter-electrode gap, a dynamic simulation of the PVECM process was carried out. The simulation results indicated that the electrolyte pressure and gas void fraction when the pulse arrived as the inter-electrode gap was narrowing clearly differed from those when the inter-electrode gap was expanding. Therefore, in addition to the traditional symmetry coupling mode, two other coupling modes called the pre-position and the post-position coupling modes are proposed which use a pulse either just before or just after the minimum inter-electrode gap. Comparative experiments involving the feed rate and machining localization were carried out to evaluate the influence of the three coupling modes. In addition, current waveforms were recorded to analyse the differences between the three coupling modes. The results revealed that the highest feed rate and the best machining localization were achieved by using the pre-position coupling mode.

Design and its Experiments of Micro Electrochemical Machining System

2010 ◽  
Vol 97-101 ◽  
pp. 2505-2508 ◽  
Author(s):  
Yuan Bo Li ◽  
Yong Jun Zhang ◽  
Zhong Ning Guo
Keyword(s):  
High Resolution ◽  
Power Supply ◽  
Pulse Width ◽  
Short Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Micro Ecm ◽  
Machining System ◽  
Short Pulse Width

A micro Electrochemical Machining (ECM) system has been developed, and macro/micro complex feed mechanism has been presented in order to achieve high-resolution. A nanosecond pulse power supply for micro-ECM has been developed, and the minimum pulse width can reach 50 ns. Complementary chopper circuit has been designed to avoid waveform distortion, which can achieve higher pulse frequency. A series of ECM experiments using the machining system have been carried out, and results of tests have proved that high-resolution spindle, and high frequency, short pulse width power supply help to achieve better quality surface, higher machining accuracy.

Machining Parameter Optimization of Aero-Engine Blade in Electrochemical Machining Based on BP Neural Network

2010 ◽  
Vol 121-122 ◽  
pp. 893-899 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji ◽  
Hong Li Liu
Keyword(s):  
Neural Network ◽  
Bp Neural Network ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Parameter Combination ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Machining ◽  
Machining Parameter

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, five main machining parameters, applied voltage, initial machining gap, cathode feed rate, electrolyte temperature and pressure difference between electrolyte inlet and outlet, have been evaluated and optimized based on BP neural network technique. From 3125 possible machining parameter combinations, 657 optimized parameter combinations are discovered. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

Micro-Hole Machined by Electrochemical Discharge Machining (ECDM) with High Speed Rotating Cathode

2011 ◽  
Vol 295-297 ◽  
pp. 1794-1799 ◽  
Author(s):  
Shao Fu Huang ◽  
Di Zhu ◽  
Yong Bin Zeng ◽  
Wei Wang ◽  
Yong Liu
Keyword(s):  
High Speed ◽  
Electrochemical Machining ◽  
304 Stainless Steel ◽  
Machining Accuracy ◽  
Micro Machining ◽  
Rotating Speed ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Holes ◽  
Micro Hole

Electrochemical discharge machining (ECDM), based on electrochemical machining (ECM) and electrodischarge machining (EDM), is an unconventional micro-machining technology. In this paper, with the use of water, the process of micro hole on ANSI 304 stainless steel machined by micro-ECDM with high speed rotating cathode is studied. The effects of machining conditions such as the cathode rotating speed and cathode diameter on the surface quality and accuracy of the shape are investigated. The results indicate that a relatively higher electrode rotating speed can improve the machining accuracy of the micro-holes and reduce the electrodes wear.

scholarly journals The Optimal Processing Parameters of Radial Ultrasonic Rolling Electrochemical Micromachining—RSM Approach

Micromachines ◽  
2020 ◽  
Vol 11 (11) ◽  
pp. 1002
Author(s):  
Kailei He ◽  
Xia Chen ◽  
Minghuan Wang
Keyword(s):  
High Efficiency ◽  
Electrochemical Machining ◽  
Processing Parameters ◽  
Pulse Frequency ◽  
Performance Criteria ◽  
Electrochemical Micromachining ◽  
Machining Parameters ◽  
Optimal Processing ◽  
Predicted Values ◽  
Working Parameters

Radial ultrasonic rolling electrochemical micromachining (RUR-EMM) is a new method of electrochemical machining (ECM). By feeding small and rotating electrodes aided by ultrasonic rolling, an array of pits can be manufactured, which is called microstructures. However, there still exists the problem of choosing the optimal machining parameters to realize the workpiece machining with high quality and high efficiency. In the present study, response surface methodology (RSM) was proposed to optimize the machining parameters. Firstly, the performance criteria of the RUR-EMM are measured through investigating the effect of working parameters, such as applied voltage, electrode rotation speed, pulse frequency and interelectrode gap (IEG), on material removal amount (MRA) and surface roughness (Ra). Then, the experimental results are statistically analyzed and modeled through RSM. The regression model adequacies are checked using the analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated and verified by experiment to maximize MRA and minimize Ra. The results show that each parameter has a similar and non-linear influence on the MRA and Ra. Specifically, with the increase of each parameter, MRA increases first and decreases when the parameters reach a certain value. On the contrary, Ra decreases first and then increases. Under the combined effect of these parameters, the productivity is improved. The experimental value of MRA and Ra is 0.06006 mm2 and 51.1 nm, which were 0.8% and 2.4% different from the predicted values.

Parameters Optimization and Experimental Study of Aero-Engine Blade in Electrochemical Machining Based on High-Risk Machining Parameter Elimination

2013 ◽  
Vol 567 ◽  
pp. 67-72 ◽  
Author(s):  
Zhi Yong Li ◽  
Zong Wei Niu ◽  
Li Li
Keyword(s):  
Electrochemical Machining ◽  
Parameters Optimization ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Object A ◽  
Parameter Combination ◽  
Aero Engine ◽  
Engine Blade ◽  
Blade Machining ◽  
Machining Parameter

Because the process of blade in electrochemical machining(EMC) can be effected by many factors, such as blade shapes, machining electrical field, electrolyte fluid field and anode electrochemical dissolution, different ECM machining parameters maybe result in great affections on blade machining accuracy. Regard some type of aero-engine blade as research object, a great deal of ECM machining parameter combination which probably result in machining failure can be eliminated based on BP neural network firstly. Furthermore, the optimized ECM machining parameter combination has been discovered. To verify the validity of the optimized ECM parameter combination, a serial of machining experiments have been conducted on an industrial scale ECM machine, and the experiment results demonstrates that the optimized ECM parameter combination not only can satisfy the manufacturing requirements of blade fully but has excellent ECM process stability.

The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3583-3586 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Three Dimension ◽  
Cathode Design ◽  
Aero Engine ◽  
Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

Electrochemical Machining of Micro-Structures With Nanosecond Pulses

2007 ◽  
Author(s):  
Zhaoyang Zhang ◽  
Di Zhu ◽  
Ningsong Qu ◽  
Kun Wang
Keyword(s):  
Pulse Duration ◽  
Electrochemical Machining ◽  
Experimental System ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Voltage Amplitude ◽  
Nanosecond Pulses ◽  
Micro Ecm ◽  
Micro Tool ◽  
Micro Structures

Electrochemical machining (ECM) is considered an advanced and promising technique due to several special advantages, such as non-contact machining without cutting force, no tool wear and heat-affected layer, etc. Base on the experimental results of micro-ECM, the influence of predominant process parameters, i.e. electrolyte concentration, pulse duration, period and voltage amplitude of power supply, on machining accuracy were investigated and discussed. Experimental showed that lower voltage amplitude and shorter pulse duration in micro-ECM process could produce more accurate micro structure shape. Using the self-developed experimental system, the micro tool-electrode and the complex micro-structures were sequentially machined. Upon the application of ultrashort voltage pulses, the letters with 20μm in line width were fabricated stably by the W tool electrode with 10μm diameter.

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