Modeling of Wire Electrochemical Micromachining

Волгин, В. М.; Lyubimov, V.V.; Кухарь, В. Д.; Давыдов, А. Д.

doi:10.1016/j.procir.2015.08.098

Cited by 21 publications

(6 citation statements)

References 17 publications

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“…In order to extend the capabilities of the WECM process and achieve optimization, the boundary element method has been considered with variously shaped static or rotating traveling wire electrodes moving with arbitrary trajectory. 58 During the fabrication of the wire electrode, as discussed earlier, the diameter of the wire can be measured indirectly by calculating the variation of the resistance of the wire. 40 Here, the final diameter of the wire electrode can be given as…”

Section: Mathematical Models and Simulationsmentioning

confidence: 99%

Review—Wire Electrochemical Machining Process: Overview and Recent Advances

Debnath

Doloi

Bhattacharyya

2019

J. Electrochem. Soc.

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Wire electrochemical machining (WECM) is a recently introduced fabrication process which is yet to be fully investigated. Preliminary studies have shown that it offers superior feasibility and capability concerning the fabrication of various microfeatures. More extensive investigations are needed to discover any associated problems with the process and to extend its applicability and efficiency by determining its limitations in order to make this process a successful fabrication technique not only in microdomains but also for macro fabrications as well. Here we begin with a detailed overview of the fundamental and technological aspects of the WECM process. We then discuss its mass transfer strategies and kinematics, which are equally important as associated operating parameters, as well as the apparatus, materials, and machining conditions, challenges, and applications. Finally, we note recent advances to guide upcoming research attempts and future investigations aimed at making this anodic dissolution process proficient and established.

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Section: Mathematical Models and Simulationsmentioning

confidence: 99%

Review—Wire Electrochemical Machining Process: Overview and Recent Advances

Debnath

Doloi

Bhattacharyya

2019

J. Electrochem. Soc.

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“…For the electrochemical cutting of thick workpieces, Volgin et al [13] performed simulations that examined whether rotation or reciprocating movement of the cathode assisted electrochemical cutting and improved machining e ciency, especially if an electrode with a noncircular (e.g., square or triangular) cross-section was adopted. It has also been found [14] that using a ring of metal wire under unidirectional movement as the cathode drags the electrolyte, facilitating the rapid removal of electrolytic products and the refreshment of the electrolyte.…”

Section: Introductionmentioning

confidence: 99%

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Yang

Fang

Hang

et al. 2021

Int J Adv Manuf Technol

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Electrochemical cutting using tube electrode with inclined holes is a machining method that directly and obliquely injects electrolyte into the machining gap through inclined jet-ow holes on the sidewall of a tube electrode, allowing the electrochemical cutting of a workpiece. To improve the machining e ciency and accuracy of this cutting technique, a method of workpiece vibration in feed direction assisted electrochemical cutting is proposed in which workpiece vibration along the feed direction rapidly and periodically changes the machining gap. The near-instantaneous increases in the machining gap promotes the waste electrolyte containing electrolytic products to ow down the machining gap. At the same time, the electrochemical reaction time under the non-uniform ow eld caused by the inclined downward injection of electrolyte is reduced. The ow eld simulation of electrolyte in machining gap indicates that the near-instantaneous increases in the machining gap can improve the ow velocity of electrolyte. Experiment demonstrates that the average feed rate can be increased by 50% and the machining e ciency is superior to that of electrochemical cutting assisted by workpiece non-vibration in feed direction. The difference between the upper and lower slit widths is reduced and the machining accuracy is improved. The effect of the vibrational amplitude and frequency on the machining result is also investigated. Finally, an array slice structure is fabricated on a stainless steel block with a crosssection of 10 mm × 10 mm at average feed rate of 6 mm/s using a vibrational amplitude and frequency of 0.1 mm and 1.5 Hz, respectively.

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Section: Introductionmentioning

confidence: 99%

Workpiece Vibration in Feed Direction Assisted Electrochemical Cutting Using Tube Electrode With Inclined Holes

Yang

Fang

Hang

et al. 2021

Preprint

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Electrochemical cutting using tube electrode with inclined holes is a machining method that directly and obliquely injects electrolyte into the machining gap through inclined jet-flow holes on the sidewall of a tube electrode, allowing the electrochemical cutting of a workpiece. To improve the machining efficiency and accuracy of this cutting technique, a method of workpiece vibration in feed direction assisted electrochemical cutting is proposed in which workpiece vibration along the feed direction rapidly and periodically changes the machining gap. The near-instantaneous increases in the machining gap promotes the waste electrolyte containing electrolytic products to flow down the machining gap. At the same time, the electrochemical reaction time under the non-uniform flow field caused by the inclined downward injection of electrolyte is reduced. The flow field simulation of electrolyte in machining gap indicates that the near-instantaneous increases in the machining gap can improve the flow velocity of electrolyte. Experiment demonstrates that the average feed rate can be increased by 50% and the machining efficiency is superior to that of electrochemical cutting assisted by workpiece non-vibration in feed direction. The difference between the upper and lower slit widths is reduced and the machining accuracy is improved. The effect of the vibrational amplitude and frequency on the machining result is also investigated. Finally, an array slice structure is fabricated on a stainless steel block with a cross-section of 10 mm × 10 mm at average feed rate of 6 mm/s using a vibrational amplitude and frequency of 0.1 mm and 1.5 Hz, respectively.

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Modeling of Wire Electrochemical Micromachining

Cited by 21 publications

References 17 publications

Review—Wire Electrochemical Machining Process: Overview and Recent Advances

Review—Wire Electrochemical Machining Process: Overview and Recent Advances

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Workpiece Vibration in Feed Direction Assisted Electrochemical Cutting Using Tube Electrode With Inclined Holes

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