Experimental study of electrophoretically assisted micro-ultrasonic machining

Lian, Haishan; Guo, Zhongning; Liu, J. W.; Huang, Zhongwei; He, Junfeng

doi:10.1007/s00170-014-6666-x

Cited by 13 publications

(5 citation statements)

References 17 publications

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“…With the development of high-precision technology, more and more high-strength, high-hardness, and hightemperature materials are needed. A number of material removal processes such as electrical discharge machining (EDM), [1][2][3] electrical ultrasonic machining (USM), 4,5 electrochemical machining (ECM), 6,7 and laser beam machining (LBM) [8][9][10] are developed for better ways of machining complex shapes in these highstrength materials.…”

Section: Introductionmentioning

confidence: 99%

Discharge current effect on machining characteristics and mechanical properties of aluminum alloy 6061 workpiece produced by electric discharging machining process

Kuo¹,

Hsu

Chen

et al. 2017

Advances in Mechanical Engineering

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In this study, machining characteristics and mechanical properties of aluminum (Al) alloy 6061 were investigated with variations in discharge currents in electrical discharge machining. The machining characteristics included the electrode wear rate, material removal rate, and roughness. Mechanical properties such as the fatigue life and surface hardness were also discussed in this work. Experimental results showed that better fatigue property of the electrical discharge machined workpiece could be obtained when the discharge current was 15 A; meanwhile, the thickness of the white layer was around 19 mm. The relationship between the thickness of the white layer and the fatigue lifetime had a very strong positive correlation. Furthermore, the repeatability and stability of the machining process were explored by the quality control chart and Shewhart control chart. The results indicated that the electrical discharge machining process under optimum operating conditions was a well-controlled procedure and stable over time.

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Section: Introductionmentioning

confidence: 99%

Discharge current effect on machining characteristics and mechanical properties of aluminum alloy 6061 workpiece produced by electric discharging machining process

Kuo¹,

Hsu

Chen

et al. 2017

Advances in Mechanical Engineering

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“…The lower MRR of 0.50 mm 3 /min was recorded for a power rating of 200 W which is much more than the higher MRR, that is, 0.198 mm 3 /min obtained by another researcher. 30 The MRR is affected significantly by the ultrasonic power. Increasing the power supplied to the ultrasonic transducer results in faster movements of the tool, which in turn increases the velocity.…”

Section: Influence Of Power Rating On Mrr Wd Angular Deviation and Ta...mentioning

confidence: 99%

Generation of array of square microcavity on quartz by ultrasonic micromachining process utilizing developed micro tool

Kumar,

Doloi,

Bhattacharyya

2024

Journal of Micromanufacturing

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Quartz possesses distinct characteristics such as exceptional hardness, high brittleness, non-conductivity, remarkable corrosion resistance, efficient transmission within specific wavelengths, strong electrical insulation properties, and the ability to withstand high temperatures and thermal shocks. These extraordinary attributes have led to its component in a wide range of applications, including the fabrication of microelectronic chips, biochips, biological channels, microfluidics, optical lenses, beam-splitting lenses, etc. Ultrasonic micromachining (USMM) is a highly promising technique within the realm of micromachining to create micro features on quartz surfaces. In the present research, array of square micro tools has been designed and developed by the wire-electrical discharge machining (EDM) process. By utilizing the developed array of square micro tools, microcavity arrays have been generated by the USMM process. The influences of process parameters on material removal rate (MRR), width deviation (WD), angular deviation, and taper of square microcavities have been investigated in the present research work. The higher MRR is obtained as 1.427 mm 3 /min at higher abrasive slurry concentration and lower WD of micro cavities is obtained as 37 µm and lower taper angle is 1.109° at 5% abrasive slurry concentration. The lower value of angular deviation is obtained as 0.836° at a lower power rating during the generation of an array of square microcavity on quartz by the USMM process. By employing array of micro tools, the accuracy of micro features can be improved, and also productivity can be increased.

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“…ER tools were used to polish metal parts (Su et al, 2016) and optical surfaces (Cheng et al, 2015) to obtain a high surface finish. Recently, they found applications in ultrasonic machining (USM) (Lian et al, 2016) and even micromachining (Chavoshi and Luo, 2015). Application of ER fluid is not widely used in direct lathe machines because of the emergence of other smart materials linked to magnetorheology which possess greater yield strength and higher operating temperature (Carlson and Sproston, 2000).…”

Section: Vibration Control Using Electrorheological Fluid (Erf)mentioning

confidence: 99%

Application of smart fluid to control vibration in metal cutting: a review

Sarath¹,

Paul

2021

WJE

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Purpose A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process. Design/methodology/approach Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods. Findings Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated. Research limitations/implications A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed. Practical implications This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. Social implications This study attempts to implement smart damper in metal cutting to control vibrations. Originality/value It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

show abstract

Experimental study of electrophoretically assisted micro-ultrasonic machining

Cited by 13 publications

References 17 publications

Discharge current effect on machining characteristics and mechanical properties of aluminum alloy 6061 workpiece produced by electric discharging machining process

Discharge current effect on machining characteristics and mechanical properties of aluminum alloy 6061 workpiece produced by electric discharging machining process

Generation of array of square microcavity on quartz by ultrasonic micromachining process utilizing developed micro tool

Application of smart fluid to control vibration in metal cutting: a review

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