Direct-writing by active tooling in electrochemical jet processing

Abstract

Recent innovations in electrochemical jet processing have caused step changes in process flexibility and precision. However, utilisation of these innovations requires the development of new machine tool technology. Presented here is a new methodology enabling the exploitation of highly customisable energy density profiles regardless of toolpath vector whilst minimising any error from the intent profile. A further approach is defined whereby active tooling allows the energy density profile to be modulated as a function of position within the toolpath, giving rise to dynamic feature creation. Adoption of this methodology allows a new design freedom within electrochemical jet processes.

Tooling aspects of micro electrochemical machining (ECM) technology: Design, functionality, and fabrication routes

“…The brass tube tool is one of the most successful examples (Zhang et al, 2021;Zhang et al, 2020a;Zhang et al, 2016b). Electrolyte renewal is achieved by using the inner hole of the tool to flush the electrolyte at high speed (Clare et al, 2018;Mitchell-Smith et al, 2019). Various techniques for the preparation of insulating films on the tool sidewall have also been developed.…”

Electrochemical jet manufacturing technology: From fundamentals to application

“…were able to micromachine circular features with a symmetric-twin profile (Fig. 12b) [69]. Due to charge accumulation on the interior radius of the circular feature, because of increased dwell, groove depths are noticeably greater.…”

“…12: (a) To retain desired profiles in complex toolpaths, rotational axes can be employed, (b) for example circular toolpaths. Taken from [69].…”

New insights on manipulating the material removal characteristics of Jet-Electrochemical machining through nozzle design

“…Similar nozzles were later leveraged by Mitchell-Smith et al [8] to produce more complex geometries than those achievable with a 'standard' cylindrical nozzle. Through leveraging these nozzle designs and introducing a rotation of the nozzle, Mitchell-Smith et al [9] produced complex and bespoke geometries were achieved by varying the rotational orientation of the non-uniform nozzles to the machine path. Liu and Qu [10] designed nozzles with different inclined ends, on both the front and trailing edges of the nozzle.…”

“…Outside of the work referred to here by Kunieda et al [4], Kawanaka and Kunieda [5], Mitchell-Smith et al [7], Mitchell-Smith et al [8], Mitchell-Smith et al [9] and Liu and Qu [10] there is limited research into nozzle geometry and flow characteristics in Jet-ECM with the possible benefits of novel nozzle design currently unrealised. For Jet-ECM to be accepted as a commercial manufacturing process, it must be stable, repeatable, reliable, and robust with an ability to accurately control the amount of material that you remove.…”