Generation of Complex Surfaces by Superimposed Multi-dimensional Motion in Electrochemical Machining

Schubert, Andreas; Hackert-Oschätzchen, Matthias; Martin, André; Winkler, Sebastian; Kuhn, Danny; Meichsner, Gunnar; Zeidler, Henning; Edelmann, Jan

doi:10.1016/j.procir.2016.02.216

Cited by 25 publications

(12 citation statements)

References 4 publications

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“…The measured data of aspect ratio and roughness for the micro pits from Figure 7a-p are listed in Table 3 (No. [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16]. It can be seen that the micro pit size and surface morphology processed by AS-EMM vary greatly under different experimental parameters.…”

Section: Resultsmentioning

confidence: 99%

“…Kunieda et al [12] proposed an EJM application using a flat electrolyte jet, which offered a new idea for micromilling and electrochemical turning. Schubert et al [13] applied superimposing multidimensional motions to a fabricated 3D complex structure with spiral geometry by EJM. Clare et al [14] studied the influence of different parameters (jet angle, electrolyte, and current density) on the machining morphology by using a nozzle that could change the jet angle and produced complex structures with better precision.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of Nozzle Inclination and Process Parameters in Air-Shielding Electrochemical Micromachining

Wang

Shang

et al. 2019

Micromachines

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Microstructures on metal surfaces with diameters of tens to hundreds of micrometers and depths of several micrometers to tens of micrometers can improve the performance of engineering parts. Air-shielding electrochemical micromachining (AS-EMM) is a promising method for fabricating these microstructures, owing to its advantage of high efficient and better localization. However, the machining performance is often influenced by the machining or nonmachining parameters in AS-EMM. In order to get a better machining result in AS-EMM, the optimization of AS-EMM, including nozzle inclination and process parameters, was studied in this paper. Firstly, nozzle inclination was optimized by the different selected air incidence angles (θ) in simulation, and θ = π/4 was advised. Then, the grey relational analysis based on the orthogonal test method was used to analyze the grey relational grade for parameters and obtain the optimal parameter combination, i.e., at electrolyte velocity 5.5 m/s, gas velocity 160 m/s, and voltage 8 V. Finally, the optimization result was verified experimentally.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Optimization of Nozzle Inclination and Process Parameters in Air-Shielding Electrochemical Micromachining

Wang

Shang

et al. 2019

Micromachines

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“…Similar to using jet-ECM to generate complex surfaces by superimposed multi-dimensional motion [ 28 ] and to derive specified waviness through parameters adjustment [ 29 ], it is also possible to fabricate a pocket with the SMEFC by overlapping multiple process trajectories. In the experiments, the VG was set to 200 µm and the IEG was set to 50 µm as default unless otherwise specified.…”

Section: Smefc Machining Experiments and Discussionmentioning

confidence: 99%

Fabrication of Mesoscale Channel by Scanning Micro Electrochemical Flow Cell (SMEFC)

2017

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A unique micro electrochemical machining (ECM) method based on a scanning micro electrochemical flow cell (SMEFC), in which the electrolyte is confined beneath the tool electrode instead of spreading on the workpiece surface, has been developed and its feasibility for fabricating mesoscale channels has been investigated. The effects of the surface conditions, the applied current, the feed rate, the concentration of the electrolyte and several geometrical parameters on the machining performance have been investigated through a series of experiments. The cross-sectional profile of the channels, the roughness of the channel bottom, the width and depth of the channel, the microstructures on the machined surface and the morphologies of the moving droplet have been analyzed and compared under different machining conditions. Furthermore, experiments with different overlaps of the electrolyte droplet traces have also been conducted, in which the SMEFC acts as a “milling tool”. The influences of the electrode offset distance (EOD), the current and the feed rate on the machining performance have also been examined through the comparison of the corresponding cross-sectional profiles and microstructures. The results indicate that, in addition to machining individual channels, the SMEFC system is also capable of generating shallow cavities with a suitable superimposed motion of the tool electrode.

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“…In contrast, Jet-ECM is a shape generating technique, where the motion strategy defines the shape of machined part. Hence, no complicated cathode geometries are required for machining complex structures [1,2,3].…”

Section: Introductionmentioning

confidence: 99%

“…The electrolyte is ejected perpendicularly towards the workpiece surface surrounded by atmospheric air that forms a closed free jet. Microstructures can be machined by controlling the multidimensional motion of the nozzle [1]. The creation of microstructures can be controlled by switching the applied electric potential [4] or by controlling the gap between nozzle and workpiece surface [5].…”

Section: Introductionmentioning

confidence: 99%

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

et al. 2019

Self Cite

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Jet electrochemical machining (Jet-ECM) is a flexible method for machining complex microstructures in high-strength and hard-to-machine materials. Contrary to mechanical machining, in Jet-ECM there is no mechanical contact between tool and workpiece. This enables Jet-ECM, like other electrochemical machining processes, to realize surface layers free of mechanical residual stresses, cracks, and thermal distortions. Besides, it causes no burrs and offers long tool life. This paper presents selected features of Jet-ECM, with special focus on the analysis of the current density during the machining of single grooves in stainless steel EN 1.4301. Especially, the development of the current density resulting from machining grooves intersecting previous machining steps was monitored in order to derive systematic influences. The resulting removal geometry is analyzed by measuring the depth and the roughness of the machined grooves. The correlation between the measured product features and the monitored current density is investigated. This correlation shows that grooves with the desired depth and surface roughness can be machined by controlling current density through the adjustment of process parameters. On the other hand, current density is sensitive to the changes of working gap. As a consequence of the changes of workpiece form and size for the grooves intersecting premachined grooves as well as the grooves with a lateral gap, working gap, and current density change. By analyzing monitoring data and removal geometry results, the suitability of current density inline monitoring to enable process control is shown, especially with regards to manufacture products that should comply with tight predefined specifications.

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Generation of Complex Surfaces by Superimposed Multi-dimensional Motion in Electrochemical Machining

Cited by 25 publications

References 4 publications

Optimization of Nozzle Inclination and Process Parameters in Air-Shielding Electrochemical Micromachining

Optimization of Nozzle Inclination and Process Parameters in Air-Shielding Electrochemical Micromachining

Fabrication of Mesoscale Channel by Scanning Micro Electrochemical Flow Cell (SMEFC)

Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

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