Electrochemical jet-assisted precision grinding of single-crystal SiC using soft abrasive wheel

Chen, Zhaojie; Zhan, Shunda; Zhao, Yonghua

doi:10.1016/j.ijmecsci.2020.106239

Cited by 28 publications

(6 citation statements)

References 27 publications

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“…The comparison of the EIS data for workpieces 1 and 2 shows that the corrosion resistance of the samples decreased after both ECP and FAP. This is attributed to the removal of the PF by the abrasive particles; the same conclusion was reached in the studies published by Yang et al and Chen et al [31,32]. Similarly, the comparison of the EIS data of workpieces 2 and 3 reveals that, after another ECP treatment, the PF was regenerated on the surface, and the corrosion resistance was improved.…”

Section: Analysis Of Passivation Filmsupporting

confidence: 80%

Electrochemical Polishing of Ti6Al4V Alloy Assisted by High-Speed Flow of Micro-Abrasive Particles in NaNO3 Electrolyte

Liu

Wang

2022

Materials

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Electrochemical polishing (ECP) is an efficient and low-cost technology for polishing difficult-to-machine materials with complex structures. However, when an environmentally friendly neutral salt solution is used as the polishing electrolyte, a dense passivation film forms on the surface of passive metals, such as titanium alloy, with a serious detrimental effect on the polishing efficiency and surface quality. In this paper, we introduce an ECP method assisted by a high-speed flow of micro-abrasive particles (ECFAP). The contribution of the flowing micro-abrasive particles in the ECP process enables the electrochemical dissolution and abrasive polishing to occur simultaneously on the workpiece surface. The high-speed abrasive particles remove the passivation film formed under ECP, thereby improving the polishing efficiency and quality. We carried out the comparative tests of conventional ECP and the proposed ECFAP on a Ti6Al4V alloy in 10% NaNO3 electrolyte; the results show that, while the matrix material forms a soft high-impedance passivation film under ECP, this film is removed by the high-speed flowing abrasive particles under ECFAP. The proposed ECFAP method improves both the polishing efficiency and the surface quality. Finally, ECFAP-treated specimens with an optimum voltage of 3 V for 10 min exhibited an average surface roughness of 0.0953 µm.

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Section: Analysis Of Passivation Filmsupporting

confidence: 80%

Electrochemical Polishing of Ti6Al4V Alloy Assisted by High-Speed Flow of Micro-Abrasive Particles in NaNO3 Electrolyte

Liu

Wang

2022

Materials

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“…As a new class of abrasive tools, Structured Abrasive Tools (SATs) are establishing themselves as one of the most promising tool solutions in the fields of mechatronics, automotive, energy, and aerospace [1]. Li et al [2] reported that SATs were increasingly employed in the grinding operations of difficult-tomachine materials, especially the materials having not only good strength at high temperature but also poor thermal conductivity such as ceramics [3], glass, Ti/Ni superalloys, and carbon fiber reinforced polymers [4,5] transportation into grinding zone [6], and (ii) possibility to generate the structured surface in a fast and controllable way.…”

Section: Introductionmentioning

confidence: 99%

On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

Wang

Liu

Zhao

et al. 2023

Int J Adv Manuf Technol

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Structured Abrasive Tools (SATs) are considered as one of the nextgeneration abrasive tool solutions due to their superior ability to transport cutting fluids into grinding zones to lower grinding temperature and therefore enable high-quality machined surfaces. There are several SAT fabrication methods including mechanical, electroplating, brazing and laser-based methods.Mechanical methods can not produce SATs with small-sized structures due to significant contact forces, while electroplating has poor controllability of abrasive grain allocations. Brazing requires special machines with high-precision motion control while laser-based methods need significant efforts on laser parameter selection and optimisation. With this, here we present a Multiple-Pass Rotary Wire Electrical Discharge Machining (MPRWEDM) method to address the aforementioned limitations. We also develop a theorical model of the created kerf profile during the MPRWEDM so as to enable controllable fabrication of SATs.The model was experimentally validated, showing a decent relative error of Page 2 of 39 9.8%. The non-linear multiple-pass effect was studied both analytically and experimentally. Based on MPRWEDM, not only the SAT with designed grooves but also the structured surface (having an array of pyramid geometries) generated by the SAT were successfully created, proving the great potential of MPRWEDM in controllable production of even more advanced tools.

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“…Traditional ECG usually uses conductive grinding heads with abrasive grains for material removal 3 . In recent years, to further improve the processing quality, methods such as ultrasonic-assisted ECG 4 , 5 , electrochemical jet-assisted grinding 6 , dry electrochemical mechanical machining 7 , and abrasive-free electrochemical mechanical machining 8 have been developed, and the application of ECG in the processing of metals and semiconductor materials has been promoted by these methods. In addition, many scholars have tried to promote the matching effect of dissolution and grinding by improving the flow field distribution.…”

Section: Introductionmentioning

confidence: 99%

Flow field characteristics and experimental research on inner-jet electrochemical face grinding of SUS420J2 stainless steel

Feng

et al. 2022

Sci Rep

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Electrochemical grinding (ECG) is processed by the combination of dissolution and grinding. It is very suitable for the processing of difficult-to-cut stainless steel, but its processing performance is restricted by the matching effect of dissolution and grinding. In this work, the processing of the torus surfaces of the stainless steel shaver cap was taken as the research object. A flow field model including the through-hole structure and the rotation of the grinding head was proposed to optimize the flow field distribution and promote the uniform dissolution of materials. The flow field simulation results showed that the rotational flow formed by the high-speed rotation prolonged the electrolyte flow path and was not conducive to the discharge of electrolytic products, and the reasonable selection of the diameter and distribution of the through-hole could reduce the velocity difference. The effects of rotational speed, feed rate, and inlet pressure on the flatness and surface roughness of the torus surfaces were experimentally investigated, and a better matching effect of dissolution and grinding was obtained. Moreover, the experimental results showed that the inner-jet ECG had a good prospect in the batch processing of high-hardness stainless steel parts.

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Electrochemical jet-assisted precision grinding of single-crystal SiC using soft abrasive wheel

Cited by 28 publications

References 27 publications

Electrochemical Polishing of Ti6Al4V Alloy Assisted by High-Speed Flow of Micro-Abrasive Particles in NaNO3 Electrolyte

Electrochemical Polishing of Ti6Al4V Alloy Assisted by High-Speed Flow of Micro-Abrasive Particles in NaNO3 Electrolyte

On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

Flow field characteristics and experimental research on inner-jet electrochemical face grinding of SUS420J2 stainless steel

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