Enhancement of performance of wire electrochemical micromachining using a rotary helical electrode

Fang, Xiaolong; Zhang, Pengfei; Zeng, Yongbin; Qu, Ningsong; Zhu, Daiyin

doi:10.1016/j.jmatprotec.2015.08.014

Cited by 51 publications

(5 citation statements)

References 18 publications

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“…In the field of EDM, however, only a few works dedicated to the use of helical external geometries exist so far [2,7,27,33,[37][38][39]. In addition, the so-called helical electrodes have found their way into research on electrochemical machining (ECM) [40][41][42][43], as well as hybrid processes [44,45]. All of these research activities followed the objective of providing additional space in the lateral working gap for the evacuation of debris and gas bubbles with the aid of the external flushing channels.…”

Section: State Of the Artmentioning

confidence: 99%

“…The renewal of the electrolyte is critical for improving the process stability and dissolution rate and reducing form defects at high aspect ratios [43]. Increasing the rotational speed of the rotating helical tool electrode had a reducing effect on the working gap in both electrochemical micro-drilling [12] and electrochemical contouring, allowing for precise manufacturing of gap contours in quartz glass with an aspect ratio of A = 6.8 [43] and complex structures in steel 1.4301 [42]. Studies by TSUI ET AL.…”

Section: State Of the Artmentioning

confidence: 99%

“…Generally, improvement of the material removal characteristics can be observed when as little dielectric as possible flows in the working gap. However, if the volume flow rate is too low, the material removal process comes to a standstill because removal products are no longer removed from the gap [10] (p. 42).…”

Section: Introductionmentioning

confidence: 99%

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Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

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The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.

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Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

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Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

View full text Add to dashboard Cite

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“…However, the smooth surface of traditional tool cathodes severely limits their mass transport capability. Some researchers have demonstrated that the tool cross-sectional geometry plays an important role in the electrolyte renewal process . In particular, the use of surface-textured tool cathodes with higher adhesion energy than their smooth counterparts has been demonstrated to afford more efficient mass transport. , The adhesion energy between the solid electrode and electrolyte can also be improved by using a more hydrophilic surface .…”

Section: Introductionmentioning

confidence: 99%

Dynamic Liquid Membrane Electrochemical Modification of Carbon Nanotube Fiber for Electrochemical Microfabrication

Meng

Zeng

Zhu

2020

ACS Appl. Mater. Interfaces

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Carbon nanotube fibers (CNFs) are a promising material for use as lightweight, high-strength, electrically conducting tool cathodes in wire electrochemical micromachining (WECMM) in which a high-performance tool cathode is crucial for optimal processing performance. However, the outstanding advantages of pristine CNFs, such as fiber strength, electrical conductivity, and hydrophilic surface, have so far remained underutilized as tool cathodes in WECMM. Herein, electrochemical modification using a dynamic liquid membrane is proposed as an effective online method for functionalizing CNFs prior to WECMM. The proposed method not only improves the assembly accuracy and efficiency but also avoids unnecessary damage to the modified CNF during installation. The introduced functional groups (−OH and −COOH) effectively improved the electrical conductivity and hydrophilicity of CNFs. The influences of H2O2 concentration, applied voltage, and anodization time on the surface modification process were examined experimentally. The use of a pulsed voltage was further proposed to prevent the loss of fiber strength due to over-anodization. Finally, the use of modified CNF electrodes with good surface morphology, strength, and conductivity in WECMM was demonstrated to afford superior machining stability, efficiency, and accuracy as well as improved surface quality compared with the conventional tool cathodes.

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“…Zeng et al 9 produced slits with an aspect ratio of more than 30 by electrolyte flushing and wire traveling. Fang et al 10 enhanced electrolyte refreshment in the direction of axial depth z E-mail: binyz@nuaa.edu.cn by using a rotary helical electrode. He et al 11 used a wire electrode with surface microstructures in WECMM to strengthen mass transport and improve the homogeneity of the slits.…”

mentioning

confidence: 99%

Improving Surface Quality and Machining Efficiency of Microgrooves by WECMM in H₃PO₄-C₂H₅OH Solution

Zeng

Hang

et al. 2019

J. Electrochem. Soc.

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Microgrooves used in microelectromechanical systems (MEMS) are small, precise and usually made of hard-to-machine material, whose surface roughness significantly affects their performance and service life. Wire electrochemical micromachining (WECMM) has been used to machine them. Sometimes, it takes extra time to polish the microgrooves produced by WECMM when they couldn't meet the requirement of some special products in terms of surface quality. In this study, a new method is proposed to produce high quality surface efficiently that simultaneously implements electrochemical cutting and polishing in phosphoric acid (H 3 PO 4 ). Ethanol, which has a lower density than water, was added to the electrolyte to improve mass transport and the flatness of the microgrooves. The polarization curves were measured to explain the principle of WECMM in H 3 PO 4 solution. The effects of the composition of the electrolyte and machining parameters on curvature and surface roughness were studied theoretically and experimentally. In optimal conditions, a microgroove with a surface roughness of S a = 0.039μm and R a = 0.033μm was obtained.

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Enhancement of performance of wire electrochemical micromachining using a rotary helical electrode

Cited by 51 publications

References 18 publications

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Dynamic Liquid Membrane Electrochemical Modification of Carbon Nanotube Fiber for Electrochemical Microfabrication

Improving Surface Quality and Machining Efficiency of Microgrooves by WECMM in H₃PO₄-C₂H₅OH Solution

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Enhancement of performance of wire electrochemical micromachining using a rotary helical electrode

Cited by 51 publications

References 18 publications

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Dynamic Liquid Membrane Electrochemical Modification of Carbon Nanotube Fiber for Electrochemical Microfabrication

Improving Surface Quality and Machining Efficiency of Microgrooves by WECMM in H3PO4-C2H5OH Solution

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Improving Surface Quality and Machining Efficiency of Microgrooves by WECMM in H₃PO₄-C₂H₅OH Solution