Investigation of hole roundness-error using different electrolytes in STED process

Vats, Anuj; Dvivedi, Akshay; Kumar, Pradeep

doi:10.1080/10426914.2021.2016811

Cited by 6 publications

(4 citation statements)

References 40 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The higher EC results in the production of high sludge volume that serves as a precursor for the evolution of roundness error in the high AR holes. 20 The qualitative inspection of hole profiles obtained for different EC also hints at some connection between EC and roundness error. Further, the electric field lines emerging from the tool slit in the presence of high electrolyte concentration aid stray dissolution from the hole wall producing holes with high roundness error.…”

Section: Resultsmentioning

confidence: 89%

“…5,19 It is difficult to achieve tool feeding rates above 1 mm min −1 while using micro-tools due to the low material dissolution rates associated with micro tools. [19][20][21] The difficulty also arises from the frequent shortcircuiting between the tool and the work sample when setting the TFR above 1 mm min −1 , which deteriorates process productivity. Thus, sustaining the STED process with minimal short-circuiting and tool feed rates above 1 mm min −1 to obtain acceptable quality high aspect-ratio holes poses problems that require process tweaking.…”

Section: Methodsmentioning

confidence: 99%

“…21,25,26 The range of process parameters, such as applied voltage and electrolyte concentration (EC), were selected based on literature and pilot experiments. 13,20 The parametric ranges and the values for the input variables corresponding to the responses are shown in Table I. The Inconel 718 work samples measuring 12 mm × 25 mm × 25 mm were mechanically polished using P800 abrasive paper to obtain an even surface.…”

Section: Methodsmentioning

confidence: 99%

See 2 more Smart Citations

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

View full text Add to dashboard Cite

Shaped tube electrolytic drilling (STED) is an electrochemical machining variant that employs a tubular tool electrode to produce holes with a high aspect ratio on hard-to-machine materials. The tubular electrodes with a diameter below 1 mm produce undesired residue (center-peak) at the machining surface that hampers the machining rate. Therefore, this study attempts to improve the electrolyte flow and enhance the electrochemical dissolution through tool modification. The performance enhancement of the STED process in terms of material removal rate and average diametral overcut has been explored. The issues related to the limitations in material removal in the STED process are brought forth with the technique to resolve those difficulties. The experiments were conducted with the modified tubular tool, and the length of slits on the tool was selected based on the simulation insights and pilot study. The effects of input process parameters (applied voltage, tool feed rate, electrolyte concentration, and tool slit length) on the output responses obtained from the STED process are elaborated. Holes with diameters in the range 0.89-0.97 mm and 12 mm depth were fabricated. Further optimization of the process parameters in the design space is also presented to obtain sustainable process performance.

show abstract

Section: Resultsmentioning

confidence: 89%

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

See 1 more Smart Citation

On Performance Enhancement of the STED Process Using Modified Tool Electrode

Vats,

Tiwari,

Dvivedi

et al. 2024

J. Electrochem. Soc.

View full text Add to dashboard Cite

show abstract

“…Meanwhile, Geethapiriyan et al performed experiments on titanium alloys using STEM and showed a 17% reduction in machining roughness and a 5.3% increase in material removal rate for nickel-plated tube electrodes compared to unplated tube electrodes [21]. In another interesting study, Anuj et al indicated that adding sodium hydroxide to sodium chloride and sodium nitrate solutions resulted in a reduction in the hole roundness error [22]. Zhang et al confirmed that the utilization of an external rinse solution around the machining area effectively decreased the radius of the stray corrosion-affected area [23].…”

Section: Introductionmentioning

confidence: 99%

Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining

Sun,

Wang,

Yang

et al. 2024

Materials

View full text Add to dashboard Cite

Electrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the addition of halogen ions to the electrolyte has been used. Still, it often results in compromised machining accuracy and surface roughness. This study applied laser and shaped tube electrolytic machining (Laser-STEM) for titanium alloy drilling, where the laser was guided to the machining zone via total internal reflection. The performance of Laser-STEM using different types of electrolytes was compared. Further, the effects of laser power and pulse voltage on the machining side gap, material removal rate (MRR), and surface roughness were experimentally studied while drilling small holes in titanium alloy. The results indicated that the use of passivating electrolytes improved the machining precision, while the MRR decreased with an increase in laser power during Laser-STEM. The MRR showed an increase while using aggressive electrolytes; however, at the same time, the machining precision deteriorated with the increase in laser power. Particularly, the maximum feeding rate of 6.0 mm/min for the tool electrode was achieved using NaCl solution as the electrolyte during Laser-STEM, marking a 100% increase compared to the rate without the use of a laser. Moreover, the model and equivalent circuits were also established to illustrate the material removal mechanisms of Laser-STEM in different electrolytes. Lastly, the processing of deep small holes with a diameter of 1.5 mm, a depth of 38 mm, and a surface roughness of Ra 2 µm was achieved via Laser-STEM without the presence of a recast layer and heat-affected zones. In addition, the cross-inner flow channels in the titanium alloys were effectively processed.

show abstract