Improvement of ECM characteristics by applying ultrasonic vibration

Natsu, Wataru; Nakayama, Hisashi; Yu, Zuyuan

doi:10.1007/s12541-012-0149-5

Cited by 53 publications

(23 citation statements)

References 15 publications

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“…In the literature, there are many relevant research about tool vibration during ECM processes. Natsu et al improved both the processing speed and the machining accuracy through the application of the ultrasonic vibration to tool electrode [18]. Zhao et al proposed a tool feed mode with vibration and enhanced the machining localization and stability [19].…”

Section: Simulation Of the Ordinary Flow Channels With Vibrationmentioning

confidence: 99%

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Jiang¹,

Astronautics²

2018

International Journal of Electrochemical Science

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A bipolar plate is an important component of proton exchange membrane fuel cells (PEMFC). The fabrication of multiple slots is a key part in preparation of metallic bipolar plates. They can be produced by electrochemical machining (ECM). During the ECM process, high flow resistance occurs with the increase of slots length and depth, which will make metal hydroxide and other by-products accumulate in the outlet of electrolyte and limit the maximum feed rate of cathode. Therefore, a flow channels contraction cathode structure with variable cross-section has been proposed. It can make the flow velocity of electrolyte increase gradually in the inter-electrode gap and take away electrolysis products better. In order to remove electrolysis products further, tool vibration is applied. The flow channels contraction cathode has been determined with numerical simulations, and the comparison experimental results show that the way is effective in improving the feed rate and ensuring the uniformity of slots depth.

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Section: Simulation Of the Ordinary Flow Channels With Vibrationmentioning

confidence: 99%

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Jiang¹,

Astronautics²

2018

International Journal of Electrochemical Science

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“…Fang et al introduced a pulsating electrolyte flow to improve machining efficiency during ECM [20]. Natsu et al applied ultrasonic vibration to improve electrochemical micromachining efficiency [21].…”

Section: Influence Of Progressive-pressure Electrolyte Flow On Machinmentioning

confidence: 99%

Electrochemical Machining of Blisk Channels with Progressive-Pressure Electrolyte Flow

Zhu

et al. 2014

Materials and Manufacturing Processes

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Progressive-pressure electrolyte flow is employed to improve efficiency and accuracy of radial electrochemical machining of blisk channels. Flow field simulation indicates that the use of progressive-pressure flow gives a high electrolyte flow rate in the inter-electrode gap, allowing a high cathode feed rate without shortcut. Experiments show that the high feed rate leads to high machining efficiency. Under the progressive-pressure flow, the surface roughnesses of the convex part, concave part, and hub of channels are reduced and the machining accuracy of the hub is enhanced. Furthermore, the allowances of the hub can be reduced by using progressive-pressure electrolyte flow.

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“…Wang et al [ 22 ] and Goel [ 23 ] discovered that the ultrasonic vibration could help in reducing the hole taper and improving the machining efficiency in ECM and the jet electrochemical micro drilling process. Wataru et al [ 24 ] proposed that the horizontal–vertical composite ultrasonic vibration of the electrode shows more advantages in ECM than single direction vibration.…”

Section: Introductionmentioning

confidence: 99%

Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

Ling

Liu

et al. 2020

Micromachines

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Wire electrochemical micromachining (WECMM) technology is regarded a promising method to fabricate high aspect ratio microstructures on hard-to-machining materials, however, the by-product accumulation in the machining gap limits its application. In this paper, a new method called ultrasonic-assisted wire electrochemical micromachining (UA-WECMM) is proposed to improve the machining performance of WECMM. Firstly, a flow-field simulation in the machining gap was carried out; the results showed that the ultrasonic vibration of electrode can remarkably enhance the mass transport in the machining gap and improve the machining condition. Secondly, experiments were performed to confirm the effect of ultrasonic vibration, which illustrated that the vibration with proper amplitude can reduce the slit width and improve the morphology of machined surface. Moreover, the influence of other machining parameters were also discussed. Finally, a T-type micro connector with good surface roughness (Ra 0.286 μm) was fabricated on a 300-μm-thick 304 stainless steel workpiece and a micro gear (diameter: 3.362 mm; Ra: 0.271 μm) with an aspect ratio of 7 was fabricated on a 2-mm-thick workpiece. It is proved that the proposed ultrasonic-assisted wire electrochemical micromachining method has considerable potential and broad application prospects.

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Improvement of ECM characteristics by applying ultrasonic vibration

Cited by 53 publications

References 15 publications

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration

Electrochemical Machining of Blisk Channels with Progressive-Pressure Electrolyte Flow

Improving Machining Localization and Surface Roughness in Wire Electrochemical Micromachining Using a Rotating Ultrasonic Helix Electrode

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