Investigation of micro-drilling using electrochemical discharge machining with counter resistant feeding

Xu, Yi; Chen, Jihong; Jiang, Baoyang; Ni, Jun

doi:10.1016/j.jmatprotec.2018.02.023

Cited by 31 publications

(15 citation statements)

References 18 publications

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“…9 Another group of researchers showed that the gravity-feed system has an elastic deformation while machining based on the tool and workpiece locations; they proposed a new resistant feeding system to improve machining force conditions. 10 A similar pressurized feed ECDM was reported showing a possibility of deep hole machining with exerted pressure onto the workpiece. 11 Although simplistic in design, these methods prevent the gas film formation at the tooltip, consequently restricting the electrical discharges to only the sides of the tools.…”

Section: Introductionmentioning

confidence: 78%

Non-contact micromachining by a dynamic feed rate controlled electrochemical discharge machining process

Shrestha

Chen

Sundaram

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrochemical discharge machining (ECDM) is an emerging micromachining method to drill advanced non-conductive materials such as Hexagonal boron nitride (hBN). Physical contact of micro tools with work material could cause machining inaccuracies, excessive tool wear, and even tool breakage. In this study, a control system based on monitoring the force generated by the ECDM gas film has been developed to achieve non-contact machining of ECDM by dynamically adjusting the tool feed rate. The accuracy of the control system was verified by accelerometer and Fast Fourier Transformation (FFT) data. In the modules, it was found that a non-contact machining process requires the FFT amplitude to be lower than 42 V for a 1200 rpm tool rotation. The experimental results show consistent micro-holes with an average diameter of 650 µm and less than 20 µm error in the overcut achieved using this control system.

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Section: Introductionmentioning

confidence: 78%

Non-contact micromachining by a dynamic feed rate controlled electrochemical discharge machining process

Shrestha

Chen

Sundaram

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Material Diameter (mm) Depth (mm) Aspect ratio Reference [24] feeding mechanisms are used by the researchers, constant drilling speed (no monitoring of drilling speed); constant gap machining, closed-loop machining (no suitable control signal known so far); counter resistant feeding [26], spring feed mechanism [21] and gravity feed mechanism [27]. Among all, the gravity feeding mechanism was most frequently used, but certain drawbacks are reported in gravity feeding, such as tool breakage and drilling depth beyond 480 mm, micro cracks are developed at the bottom face of the glass which could be due to the loading of the contact force [28].…”

Section: Snomentioning

confidence: 99%

Effect of loose abrasive mixed electrolyte on the aspect ratio of blind holes drilled in soda-lime glass by ECDM process

Vemula

Chak

2020

Manufacturing Rev.

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Electro-Chemical Discharge Machining (ECDM) process has the potential to machine various features and 3D surfaces on glass. However, machining of high aspect ratio micro holes is a challenging problem in ECDM process. In ECDM process, the machining rate mainly depends on the availability of the electrolyte at the electrode tip. Machining accuracy like taper, entry and exit diameter of the hole at high depths is rigorously affected due to lack of electrolyte at the machining zone resulting in more taperness. Low surface qualities (i.e. more over cut and tapered micro holes) are few limitations of the process. To enhance the machining capabilities a novel approach of PMECDM has been conducted. Present study is mainly focused on behavior of abrasive particles while machining soda lime glass, also studied effect of process parameters on the responses such as machining depth, outer diameter and aspect ratio. Also, the study led to analyze the effect of thermal properties of abrasives on machining performance of ECDM process. The maximum machined depth achieved was 2.31 mm in 5 min, and tremendous reduction of outer diameter from 1237.37 μm to 712.8 μm. Response surface methodology has been used to plan the experiments and ANOVA has been used to analyze the impact of each process parameters on machined depth and outer diameter of the micro holes.

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“…The most frequent use of this method was drilling among the various applications of the ECDM. 10,11 Usually, the drilling behavior of ceramics causes excessive wear of the tools, elevated cutting forces, and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

“…The electrochemical discharge approach has been commonly used to manufacture non‐conductive hard materials that could not be machined directly. The most frequent use of this method was drilling among the various applications of the ECDM 10,11 . Usually, the drilling behavior of ceramics causes excessive wear of the tools, elevated cutting forces, and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Prediction on enhanced electrochemical discharge machining behaviors of zirconia‐silicon nitride using hybridDNNbased spotted hyena optimization

Manoharan

Sekar²

2022

Intl J of Energy Research

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Summary In this work, zirconia composite is machined by the unconventional Electrochemical Discharge Machining (ECDM). Normally, the machining of zirconia is an inconvenient process due to its increased hardness and maximum machining time. The ECDM of zirconia‐silicon nitride is done by varying the input parameters such as electrolytic concentration, voltage, and duty cycle. The measured output machined parameters are material removal rate (MRR), Overcut (OC), and Tool wear rate (TWR). In Response Surface Methodology (RSM), the Box Behnken method is used to plan the experimental design of this work. The parameter optimization is conducted using RSM. Besides, the experimented machining performances are validated using hybrid Deep Neural Network‐based Spotted Hyena optimization (DNN‐SHO) done in MATLAB platform version 2020 a. From the findings, the voltage and electrolytic concentration are identified as signified parameters for improving the ECDM performances from the RSM analysis. The obtained favorable machining performances are 0.371 mg/min of MRR, 162.2 μm of OC, and 0.26 mg/min of TWR. The predicted results from the proposed DNN‐SHO for the MRR are 0.402 mg/min, OC is 152.98 μm, and TWR is 0.21 mg/min. The proposed DNN‐SHO outcomes are in perfect agreement with the experimented values and are more superior to the RSM, DNN, and DNN‐PSO based prediction approaches.

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Investigation of micro-drilling using electrochemical discharge machining with counter resistant feeding

Cited by 31 publications

References 18 publications

Non-contact micromachining by a dynamic feed rate controlled electrochemical discharge machining process

Non-contact micromachining by a dynamic feed rate controlled electrochemical discharge machining process

Effect of loose abrasive mixed electrolyte on the aspect ratio of blind holes drilled in soda-lime glass by ECDM process

Prediction on enhanced electrochemical discharge machining behaviors of zirconia‐silicon nitride using hybridDNNbased spotted hyena optimization

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