Flushing Enhancement with Vibration and Pulsed Current in Electrochemical Machining

Feng, Zhujian; Orona-Hinojos, J. M.; Villanueva, Pedro Pérez; Lomeli, Paul; Hung, Wayne

doi:10.26776/ijemm.02.04.2017.01

Cited by 3 publications

(2 citation statements)

References 19 publications

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“…The performance of ECP can also be enhanced by switching the applied direct current to pulsed current. The additional off-time in pulsed current allowed effective flushing of debris/ions and refreshing of new electrolyte to the anodic surface [19][20][21][22][23]. When combining with ultrasonic vibration, the cavitation effect led to effective flushing and improved surface finish of ECP parts [24].…”

Section: Introductionmentioning

confidence: 99%

Electrochemical Polishing of Extruded and Laser Powder-Bed-Fused Inconel 718

Jain

Hyder²,

Corliss³

et al. 2021

IJEMM

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Electro-chemical polishing (ECP) was utilized to produce sub-micron surface finish on Inconel 718 parts manufactured by Laser Powder-Bed-Fusion (L-PBF) and extrusion methods. The L-PBF parts had very rough surfaces due to semi-welded powder particles, surface defects, and difference layer steps that were generally not found on surfaces of extruded and machined components. This study compared the results of electro-polishing of these differently manufactured parts under the same conditions. Titanium electrode was used with an acid-based electrolyte to polish both the specimens at different combinations of pulsed current density, duty cycle, and polishing time. Digital 3D optical profiler was used to assess the surface finish, while optical and scanning electron microscopy was utilized to observe the microstructure of polished specimens. At optimal condition, the ECP successfully reduced the surface of L-PBF part from 17 Âµm to 0.25 Âµm; further polishing did not improve the surface finish due to different removal rates of micro-leveled pores, cracks, nonconductive phases, and carbide particles in 3D-printed Inconel 718. The microstructure of extruded materials was uniform and free of processing defects, therefore can be polished consistently to 0.20 Âµm. Over-polishing of extruded material could improve its surface finish, but not for the L-PBF material due to defects and the surrounding micro-strain.

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Section: Introductionmentioning

confidence: 99%

Electrochemical Polishing of Extruded and Laser Powder-Bed-Fused Inconel 718

Jain

Hyder²,

Corliss³

et al. 2021

IJEMM

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“…The non-contact nature of the process with nearly force free machining helps to eliminate mechanical stresses, chatter, and vibration problems during machining [8][9]. Micro-EDM, wire EDM, micro wire EDM and micro electro chemical machining are some of the examples of micromachining operation which are used for the micro scale industries for micro fabrication [2,[10][11][12]. Wire EDM and micro wire EDM are special types of EDM since they have the ability to cut complex shapes and tapered geometries with high performance [3].…”

Section: Introductionmentioning

confidence: 99%

Precision Control of Kerf in Metal Cutting Using Dry Micro WEDM: Issues and Challenges

Ali

Banu

Rahman

et al. 2018

KEM

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Micro dry wire EDM is a process where gas is used as the dielectric fluid instead of a liquid. In this process certain modifications of a wire EDM are needed during the machining operation to achieve stable machining. Optimizing kerf to get high dimensional accuracy is one of the critical issues in micro dry wire EDM. The fundamental modelling for optimum kerf using micro dry wire EDM has not been formulated yet. Due to the complex phenomenon, the prediction of optimum kerf in a micro dry wire EDM process is rather difficult. Hence, the main objectives of this research are to improve the micro dry wire EDM process and to develop mathematical models for optimum kerf using micro dry wire EDM. During the process improvement of micro dry wire EDM, various machining setup will be involve in order to achieve the most stable process. The most stable machining process will be used to prove the developed mathematical models. A mathematical relationship between kerf and process parameters is anticipated. The mathematical models in conjunction with experimental data will eventually produce the desired theory. The developed process and mathematical model of kerf is a breakthrough in fabricating products such as micro tools, molds etc. with optimum kerf and high dimensional accuracy. The successful completion of this research will contribute to the environmental friendly micromachining process.

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