Quality Enhancement with Ultrasonic Wave and Pulsed Current in Electrochemical Machining

Patel, Jigar Bimal; Feng, Zhujian; Villanueva, Pedro Pérez; Hung, Wayne

doi:10.1016/j.promfg.2017.07.013

Cited by 11 publications

(7 citation statements)

References 10 publications

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“…Many researchers have performed experimental investigation on the effect of vibration on ECM. In an ultrasonicassisted ECM system, controlled vibration of either the tool electrode or electrolyte to agitate the abrasives suspended in the electrolyte had shown to improve surface finish of the workpiece [16]. A study of the geometry and type of electrode that resulted in a well-polished surface (0.7 µm Ra) was reported and the effect of ultrasonic energy was acknowledged [17].…”

Section: Literature Reviewmentioning

confidence: 99%

“…In traditional vibration-assisted ECM the anode/cathode were vibrated in the vertical direction, thus the resulted by-products, that deposited on either electrode due to gravity, would hinder ion transport mechanism. A horizontal and vibrationassisted ECM was proposed as a remedial solution [6,16,[19][20][21], in which a workpiece vibrated in the horizontal direction instead of the vertical direction to facilitate flushing of the resulted by-products.…”

Section: Literature Reviewmentioning

confidence: 99%

“…− Applying a high voltage to increase migration rates [2][3][4] − Applying pulsed current instead of using direct current [5][6][7][8] − Increasing high electrolyte flow rates to increase diffusion rates [3,9] − Vibrating of either workpiece or electrode at low vibration frequency to increase the convection rates [8,[10][11][12][13][14]] − Applying ultrasonic vibration of electrode or via electrolyte [13,15,16]. Convection is the most significant factor that affects ion transport mechanism.…”

Section: Introductionmentioning

confidence: 99%

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Computer Simulation of Low Frequency Vibration in Electrochemical Machining

Hung

Feng²,

Lomeli³

2021

IJEMM

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This research studies how particles transport between low frequency vibrating electrodes during electrochemical machining (ECM). The ANSYS Fluent software was used to study the particle speed while the Star CCM+ software was utilized to study particle interactions during vibration-assisted ECM process. A series of simulations were conducted to calculate the particle average flushing speed. Collided particles either gained momentum or deflected their trajectories to accelerate in the flow of electrolyte. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at 40 Hz vibration frequency and 10 µm vibration amplitude. Such higher flushing speed of particles improved machining depth (material removal rate) and produced a sharper machined profile. Experiment results confirmed that the maximum machining depth and minimum taper angle were obtained when vibrating the anodic workpiece at 40 Hz and 10 µm amplitude. Machining depth and ECM material removal rate had a positive correlation with the average flushing speed. A sharper ECM’ed profile was achieved since the taper angle was favorably reduced at high average flushing speed.

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Section: Literature Reviewmentioning

confidence: 99%

Section: Literature Reviewmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Computer Simulation of Low Frequency Vibration in Electrochemical Machining

Hung

Feng²,

Lomeli³

2021

IJEMM

Self Cite

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“…Other researchers [14] used ultrasonic probe to send 20 kHz ultrasonic wave to workpiece surface via flowing electrolyte. The authors used 6061-T6 aluminum workpieces of 60 mm × 50 mm × 6.3 mm, Teflon coated stainless steel tubular electrode with 9.5 mm outer diameter and 8.9 mm inner diameter, 1 mol/L KBr electrolyte, 22 A peak current.…”

Section: Effect Of Ultrasonic Vibrationmentioning

confidence: 99%

Flushing Enhancement with Vibration and Pulsed Current in Electrochemical Machining

Feng

Orona-Hinojos²,

Villanueva³

et al. 2017

IJEMM

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This research aims to understand flushing of by-products in electrochemical machining (ECM) by modeling and experimentally verifying mechanism of particle transport in inter-electrode gap under low frequency vibration. A series of hole were drilled on steel plates to evaluate the effect of vibration on material removal rate and hole quality. Infinite focus optical technique was used to capture and analyze the three-dimensional images of ECM'ed features. Experimental results showed that maximum machining depth and minimum taper angle can be achieved when vibrating the workpiece at 40 Hz and 10 µm amplitude. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at this vibration frequency and amplitude. Machining depth and material removal rate has a positive correlation with the average flushing speed. Sharper ECM’ed profile is obtained since the taper angle is favorably reduced at high average flushing speed.

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“…Bhattacharyya et al [ 15 ] developed a microtool vibration system for electrochemical micromachining and studied the influence of vibration frequency, pressure amplitude, and the concentration of the electrolyte solution on the precision of micro-hole processing. To enhance ECM, Patel et al [ 16 ] combined the pulsed current and ultrasonic to drill deep holes in 6061-T6 aluminum. This technique enhanced part quality by reducing the surface roughness parameter (Ra) from 2.5 to 1 μm and the taper angle of the drilled holes from 11° to 1°.…”

Section: Introductionmentioning

confidence: 99%

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

Wang

Zhang

et al. 2020

Materials

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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.

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Quality Enhancement with Ultrasonic Wave and Pulsed Current in Electrochemical Machining

Cited by 11 publications

References 10 publications

Computer Simulation of Low Frequency Vibration in Electrochemical Machining

Computer Simulation of Low Frequency Vibration in Electrochemical Machining

Flushing Enhancement with Vibration and Pulsed Current in Electrochemical Machining

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

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