Design and implementation of an electrode feed rate control system in the electrochemical drilling process

Özerkan, Hacı Bekir; Çoğun, Can

doi:10.1007/s40430-022-03667-9

Cited by 6 publications

(4 citation statements)

References 20 publications

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“…Various strategies for controlling tool motion to achieve the desired IEG values in the ECM process were suggested in the literature. 27 However, in performing the ECPP operation for this study, motion control in both the longitudinal (Zaxis) and radial (X or Y axes) directions was deemed unnecessary. This decision was rooted in the tool's non-fed approach; rather than being fed, it was precisely plunged into the initial hole at a predetermined Z-axis coordinate corresponding to the hole depth, maintaining a stationary position thereafter.…”

Section: Methodsmentioning

confidence: 99%

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Singh,

Rakurty,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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Electrical discharge micromachining (EDM) poses challenges to the fatigue-life performance of machined surfaces due to thermal damage, including recast layers, heat-affected zones, residual stress, micro-cracks, and pores. Existing literature proposes various ex-situ post-processing techniques to mitigate these effects, albeit requiring separate facilities, leading to increased time and costs. This research involves an in-situ sequential electrochemical post-processing (ECPP) technique to enhance the quality of EDMed micro-holes on titanium. The study develops an understanding of the evolution of overcutting during ECPP, conducting unique experiments that involve adjusting the initial radial interelectrode gap (utilizing in-situ wire-electrical discharge grinding) and applied voltage. Additionally, an experimentally validated transient finite element method model is developed, incorporating the passive film formation phenomenon for improved accuracy. Compared to EDM alone, the sequential EDM-ECPP approach produced micro-holes with superior surface integrity and form accuracy, completely eliminating thermal damage. Notably, surface roughness (Sa) was reduced by 80% after the ECPP. Increasing the voltage from 8 to 16 V or decreasing the gap from 60 to 20 µm rendered a larger overcut. This research's novelty lies in using a two-phase dielectric (water-air), effectively addressing dielectric and electrolyte cross-contamination issues, rendering it suitable for commercial applications.

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Section: Methodsmentioning

confidence: 99%

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Singh,

Rakurty,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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“…The control of IEG is essential to maintain machining stability, Özerkan et al 28 designed an IEG adjustment system based on the measurement of the machining current value, which realizes the dynamic adjustment of the IEG through the current data feedback. In this study, a similar method to the most commonly used IEG control method described above was used, the IEG distance was controlled using a contact adjustment method and monitored in real time by the machine's displacement feedback platform.…”

Section: Experiments and Methodologymentioning

confidence: 99%

Effects of Circular Hydraulic Jump on the Material Removal Characteristics of Jet Electrochemical Machining

Wang,

Shen,

Zhou

et al. 2023

J. Electrochem. Soc.

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Jet electrochemical machining (Jet-ECM) is a potential precision machining method. Due to the advantages of non-stress-free machining and high flexibility, it is widely used in surface finishing and complex structural machining. However, the “w” shaped removal profile and wide removal range caused by inappropriate process parameters reduce the stability and localizability of Jet-ECM. Here, the material removal characteristics of Jet-ECM were investigated both theoretically and experimentally. A multi-physics field simulation model for Jet-ECM was established, and the overall shape of the circular hydraulic jump (CHJ), current density distribution and workpiece deformation were calculated. The effects of CHJ on the material removal characteristics were investigated by experiments with jet flow rate and inter-electrode gap distance. The results reveal the qualitative relationship between CHJ states and process parameters and give the range of parameters that can form a stable CHJ and ensure a Gaussian shaped removal profile and a narrower removal range. This study provides theoretical guidance on the process parameters of Jet-ECM to improve its processing stability and localizability, which is significant for the accuracy of surface finishing and the controllability of complex structural machining, promoting the further application of Jet-ECM.

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“…Meanwhile, electrochemical machining (ECM) is not limited by the mechanical properties of the conductive material and can achieve high surface integrity without experiencing tool wear [11,12]. Unlike other methods, ECM also has the ability to avoid the formation of both the recast layers and heat-affected zones [13].…”

Section: Introductionmentioning

confidence: 99%

Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining

Sun,

Wang,

Yang

et al. 2024

Materials

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Electrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the addition of halogen ions to the electrolyte has been used. Still, it often results in compromised machining accuracy and surface roughness. This study applied laser and shaped tube electrolytic machining (Laser-STEM) for titanium alloy drilling, where the laser was guided to the machining zone via total internal reflection. The performance of Laser-STEM using different types of electrolytes was compared. Further, the effects of laser power and pulse voltage on the machining side gap, material removal rate (MRR), and surface roughness were experimentally studied while drilling small holes in titanium alloy. The results indicated that the use of passivating electrolytes improved the machining precision, while the MRR decreased with an increase in laser power during Laser-STEM. The MRR showed an increase while using aggressive electrolytes; however, at the same time, the machining precision deteriorated with the increase in laser power. Particularly, the maximum feeding rate of 6.0 mm/min for the tool electrode was achieved using NaCl solution as the electrolyte during Laser-STEM, marking a 100% increase compared to the rate without the use of a laser. Moreover, the model and equivalent circuits were also established to illustrate the material removal mechanisms of Laser-STEM in different electrolytes. Lastly, the processing of deep small holes with a diameter of 1.5 mm, a depth of 38 mm, and a surface roughness of Ra 2 µm was achieved via Laser-STEM without the presence of a recast layer and heat-affected zones. In addition, the cross-inner flow channels in the titanium alloys were effectively processed.

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Design and implementation of an electrode feed rate control system in the electrochemical drilling process

Cited by 6 publications

References 20 publications

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Effects of Circular Hydraulic Jump on the Material Removal Characteristics of Jet Electrochemical Machining

Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining

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