Microhole drilling through electrochemical processes: A review

Rahman, Md. Zishanur; Das, Alok Kumar; Chattopadhyaya, Somnath

doi:10.1080/10426914.2017.1401721

Cited by 39 publications

(12 citation statements)

References 158 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Figure 11 shows the impact of voltage and feed rate on hole diameter by simulation and experiments. Both simulation and experiments indicate that the hole diameter increases with applied voltage but decreases with feed rate, which is according with Equation (13). When the feed rate is constant, the higher applied voltage, the higher current density in the machining, and the ability of the electrochemical reaction is stronger to remove the materials so that the hole diameter is larger.…”

Section: Influence Of Ultrasonic Amplitude Influence Of Applied Voltamentioning

confidence: 65%

“…As shown in Equation (13), when the other machining conditions remain constant, the hole diameter increases with diameter of the ball-end, applied voltage and electrical conductivity of electrolyte but decreases with feed rate of tool electrode as well as the resistance of passive oxide film and electrolyte.…”

Section: Mathematical Modelmentioning

confidence: 99%

“…However, nickel-based superalloys are hard to machine due to the low thermal conductivity and high temperature strength [4,5], which could cause poor surface quality, serious tool wear, and low productivity in traditional machining [6][7][8]. As for a few non-traditional machining methods, laser machining [9,10] and electrical discharge machining (EDM) [11,12] which based on heat melting usually produce micro cracks, recast layers, and heat affected zones, while electrochemical machining (ECM) [13] could not meet the demands of high precision machining due to stray current corrosion.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

et al. 2020

View full text Add to dashboard Cite

Electrochemical grinding (ECG) technique composed of electrochemical machining (ECM) and mechanical grinding is a proper method for machining of difficult-to-cut alloys. This paper presents a new ultrasonic assisted electrochemical drill-grinding (UAECDG) technique which combines electrochemical drilling, mechanical grinding, and ultrasonic vibration to fabricating high-quality small holes on superalloy. By applying ultrasonic vibration to high-speed rotating electrode in ECG, machining stability, efficiency, and surface quality can be obviously improved. Firstly, the electrochemical passive behavior of superalloy is studied, the mathematical model and simulation of gap electric field are established. Then, several experiments are conducted to investigate the influence of applied voltage, feed rate and ultrasonic amplitude on the machining quality. The balance of material removal between electrochemical reaction and mechanical grinding is achieved by optimizing the machining parameters. It reveals that the surface quality as well as machining stability and efficiency can be significantly improved by applying rotating ultrasonic vibration to the ECG process. Finally, several small holes of high quality have been machined successfully along with surface roughness of hole sidewall decreases from Ra 0.99 μm to Ra 0.14 μm by UAECDG.

show abstract

Section: Influence Of Ultrasonic Amplitude Influence Of Applied Voltamentioning

confidence: 65%

Section: Mathematical Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

et al. 2020

View full text Add to dashboard Cite

show abstract

“…At present, research on cathode materials mainly focus on the application of single cathode material in electrochemical machining, such as brass, copper alloy, or iron alloy, while there has been less research in the field of electrochemical machining [ 27 , 28 , 29 , 30 ]. Another main reason is that as 304 stainless steel, brass, and tungsten steel are the most common tool electrodes [ 31 ], the focus is generally put on the optimization of the cathode structure during the design of the electrochemical machining cathode, while the influence of the cathode material on electrochemical machining is often ignored. Furthermore, different cathode materials also have different chemical components and reaction mechanisms, which result in different machining capacities.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Influence of Tool Electrode Material on Electrochemical Micromachining of 304 Stainless Steel

Bian

et al. 2021

Materials

View full text Add to dashboard Cite

Different cathode materials have different surface chemical components and machining capacities, which may finally result in different machining quality and machining efficiency of workpieces. In this paper, in order to investigate the influence of cathode materials on the electrochemical machining of thin-walled workpiece made of 304 stainless steel, five cylindrical electrodes are used as the target working cathodes of electrochemical machining to conduct experiments and research, including 45# steel, 304 stainless steel, aluminum alloy 6061, brass H62, and tungsten steel YK15. The stray current corrosion, taper, and material removal rate were used as the criteria to evaluate the drilling quality of efficiency of a thin-walled workpiece made of 304 stainless steel. The research results show that from the perspectives of stray current corrosion and taper, aluminum alloy 6061 is an optimal tool cathode, which should be used in the electrochemical machining of thin-walled workpieces made of 304 stainless steel; on the aspect of material removal rate, the 45# steel, 304 stainless steel, and aluminum alloy 6061 present close material removal rates, all of which are higher than that of brass H62 and tungsten steel YK15. Based on comprehensive consideration of both machining quality and machining efficiency, the aluminum alloy 6061 is the best option as the cathode tool in the electrochemical machining of thin-walled workpieces made of 304 stainless steel.

show abstract

“…ECM occupies an essential position in micro-hole array processing due to its high machining performance. ECM ensures a higher stability of the machining process without the heat-affected zone generation, machining stress, and the limitation of material hardness [7,8]. As an ECM technology, through-mask ECM (TMECM) is primarily intended for micro-hole array processing with restraining the machinable region by using a thin insulation sheet with a specific pattern, and TMECM has been widely used to produce micro-structured components Materials 2020, 13, 5780 2 of 13 such as micro-dimples, hole arrays and micro-grooves.…”

Section: Introductionmentioning

confidence: 99%

Ultrasound-Assisted Through-Mask Electrochemical Machining of Hole Arrays in ODS Superalloy

Wang

Zhang

et al. 2020

Materials

View full text Add to dashboard Cite

Micro-hole arrays have found wide applications in aerospace, precision instruments, and biomedicine. Among various methods of their production, including mechanical, laser, and electrical discharge, electrochemical machining (ECM) is considered the most lucrative due to its wide processing range, high surface quality, and excellent productivity. In particular, ultrasound-assisted through-mask ECM exhibits an enhanced machining precision due to ultrasonic cavitation, which promotes the removal of the electrolytic products and bubbles. In this study, the equation of cavitation bubble oscillation was derived and numerically solved to study the influence of six different parameters on the ultrasonic cavitation and electrolysis process, and their optimal values were determined. The feasibility of the proposed ultrasound-assisted through-mask ECM technology with the optimized parameters was experimentally corroborated by the fabrication of a high-quality hole array in an oxide dispersion strengthened (ODS) MA956 superalloy.

show abstract

Microhole drilling through electrochemical processes: A review

Cited by 39 publications

References 158 publications

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy

Experimental Study on the Influence of Tool Electrode Material on Electrochemical Micromachining of 304 Stainless Steel

Ultrasound-Assisted Through-Mask Electrochemical Machining of Hole Arrays in ODS Superalloy

Contact Info

Product

Resources

About