Fabrication of semi-circular micro-groove on titanium alloy surface by through-mask electrochemical micromachining

Wang, G.Q.; Zhu, Daiyin; Li, H.S.

doi:10.1016/j.jmatprotec.2018.03.015

Cited by 23 publications

(3 citation statements)

References 18 publications

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“…Zhao et al created deep narrow grooves in titanium alloys using a hollow slice cathode during ECM [14]. Wang et al investigated the impact of mask aspect ratio on microgroove pro les during through-mask ECM, processing a group of 30 semi-circular microgrooves with a 52.59 mm radius in cross-section on titanium alloys [15]. Zhang et al crafted a complex groove of 1.32 mm width and 8.05 mm depth through single-pass milling with a tube electrode.…”

Section: Introductionmentioning

confidence: 99%

Processing of titanium alloys with improved efficiency and accuracy by laser and electrochemical machining

Yang,

Wang,

Sun

et al. 2024

Int J Adv Manuf Technol

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The fabrication of microstructures with high e ciency and accuracy on titanium alloys presents signi cant challenges due to stringent quality requirements. Hybrid laser and electrochemical machining (LECM) has emerged as a viable solution for e cient and precise processing of titanium alloys. This study investigates the material removal mechanism of titanium alloys during LECM, analyzing the machining characteristics under the combined in uence of laser processing and electrochemical machining. The impacts of voltage, laser power, and feeding rate on aspects such as aspect-ratio, accuracy, e ciency, and surface roughness are examined. Results reveal that synchronous laser irradiation effectively accelerates electrochemical corrosion rates, enhancing the removal capability of the passive lm. Notably, LECM outperforms pure ECM, demonstrating signi cant improvements in parameters such as aspect-ratio (394.4% increase), material removal rate (140% increase), and aspectratio (172.8% increase). Lower laser power is favored for high-precision LECM. An electric circuit model elucidates the titanium alloy material removal mechanism in LECM. Additionally, the study proposes the use of gradient laser power for fabricating high-aspect-ratio structures with e ciency and accuracy. The research successfully fabricates microstructures with elevated aspect-ratio and at bottoms on titanium alloys.

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Section: Introductionmentioning

confidence: 99%

Processing of titanium alloys with improved efficiency and accuracy by laser and electrochemical machining

Yang,

Wang,

Sun

et al. 2024

Int J Adv Manuf Technol

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“…Besides, through-mask electrochemical micromachining (TMEMM) is another promising method to generate arrayed surface texture, with the workpiece surface covered by a patterned mask through lithographic process and the machining region exposed [7]. Using this method, Wang et al [8] gathered 30 micro grooves with different dimensions on titanium alloy surface. Air-shielding electrochemical micromachining (AS-EMM) can be counted as a third new processing for micro structure where the coaxial assistant gas supplies power to the radial electrolyte flow and keeps the hydraulic jump away from the jet impact area [9], so as to improve the localized material erosion [10].…”

Section: Introductionmentioning

confidence: 99%

Mechanism of 6061 Aluminium Material Erosion in USEMM

Tong

Wang

et al. 2021

Preprint

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Micro-structure on metal surface can be created with high precision and good surface quality by ultrasonic-assisted electrochemical micromachining (USEMM). One of the prevalent material removal mechanisms in ultrasonic machining (UM) is cavitation erosion. However, the mechanism of material erosion is not clear and worth investigating. This study of the mechanical and chemical effects of the ultrasonic vibration in 6061 aluminium alloy is targeted to reveal the material processing mechanism in USEMM. Based on the built model, the velocity of micro-jet produced near the workpiece surface by ultrasonic cavitation reaches up to 350 m/s when bubble collapses computed by software MATLAB. The impact of micro jet produces plastic micro-pits on the metal surface and the convex peak around the edge of the pits, which is verified in ABAQUS software. The metallographic microscope and curves of the electrochemical polarization behaviour results indicate a significant grain refinement and a marked increase of anodic dissolution current, as well as a weaker resistance than the original workpiece in NaNO3 electrolyte during UM. The current-time curve during machining demonstrates the passive layer forms on the metal surface and then breaks down at the time of less than 0.0066s in USEMM. Micrographs of scanning electron microscope (SEM) of the machined surface in different stages show that many uniform and flat pits are formed in USEMM, compared with the local uneven pits in EMM.

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“…Today, titanium alloys are commonly processed by laser machining [16], electrodischarge machining (EDM) [17,18], electrochemical machining (ECM) [19], laser-assisted machining (LAM) [20,27], and minimum quantity lubrication (MQL)-assisted machining [21]. For example, Meng et al used a 1064 nm laser to fabricate a blind hole array with a columnar entrance and a hemispherical bottom on a Ti6Al4V alloy.…”

Section: Introductionmentioning

confidence: 99%

Micromilling of Ti6Al4V alloy assisted by plasma electrolytic oxidation

Hu¹,

Meng²,

Luan³

et al. 2020

J. Micromech. Microeng.

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This paper develops a novel processing method of plasma electrolytic oxidation-assisted micromilling (PEOAM). Electrolyte solutions with KH2PO4, NaAlO2, or Na2SiO3 as the main component are designed, and three types of oxide films are grown on the surface of a Ti6Al4V alloy in situ by means of plasma electrolytic oxidation. The morphology and composition of the oxide films are characterized by scanning electron microscope and energy dispersive spectrum. Additionally, the cutting force and surface roughness of PEOAM are measured by dynamometer and white light interferometer, respectively. A comparison between PEOAM and conventional micromilling in terms of cutting force, tool wear, chips, and surface roughness is conducted, with results showing that oxide films with about 20 μm thickness are loose and porous, their hardness decreasing to a minimum of 1.12 GPa, which corresponds to 23.3% of the original hardness value. At the axial cutting depth of 18 μm, compared to the Fx, Fy , and Fz values of the Ti6Al4V alloy substrate, the average milling forces of the NaAlO2 oxide film are the most significantly reduced (35.1%, 15.7%, and 94.8% of the original values, respectively). At the axial cutting depth of 25 μm, the surface roughness (R a) value of PEOAM is reduced by 0.08–0.12 μm. Consequently, under the same cutting parameters, PEOAM can effectively reduce the cutting force, prolong the service life of the tool, and improve surface quality.

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Fabrication of semi-circular micro-groove on titanium alloy surface by through-mask electrochemical micromachining

Cited by 23 publications

References 18 publications

Processing of titanium alloys with improved efficiency and accuracy by laser and electrochemical machining

Processing of titanium alloys with improved efficiency and accuracy by laser and electrochemical machining

Mechanism of 6061 Aluminium Material Erosion in USEMM

Micromilling of Ti6Al4V alloy assisted by plasma electrolytic oxidation

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