Selected Aspects of Electrochemical Micromachining Technology Development

Skoczypiec, Sebastian; Lipiec, Piotr; Bizon, Wojciech; Wyszyński, Dominik

doi:10.3390/ma14092248

Cited by 13 publications

(4 citation statements)

References 25 publications

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“…In the process of ECG, the contribution of mechanical and electrochemical energy fields in material removal can be regulated by adjusting parameters, such as the applied voltage and the feed rate. Therefore, the process of ECG can obtain a bigger material removal rate (MRR) than mechanical grinding (MG) and be more precise than electrochemical machining (ECM) [11,12]; it is an ideal technology for the efficient-precise machining of difficult-to-machine materials that are easy to passivate.…”

Section: Introductionmentioning

confidence: 99%

“…In the process of ECG, the contribution of mechanical and ele chemical energy fields in material removal can be regulated by adjusting parameters, as the applied voltage and the feed rate. Therefore, the process of ECG can obtain a bi material removal rate (MRR) than mechanical grinding (MG) and be more precise electrochemical machining (ECM) [11,12]; it is an ideal technology for the efficient-pr machining of difficult-to-machine materials that are easy to passivate. For the last decades, considerable studies on the ECG process have been condu A. Hascalik [2] performed a precise ECG process on the Ti-6Al-4V surface after elect discharge machining (EDM), applying low voltages in the range of 2-8 V, and a de free machined surface with a low surface roughness of 0.06 µm was obtained.…”

Section: Introductionmentioning

confidence: 99%

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An Investigation of the Efficient–Precise Continuous Electrochemical Grinding Process of Ti–6Al–4V

Yang,

Ming,

Niu

et al. 2024

Materials

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Titanium alloys have many excellent characteristics, and they are widely used in aerospace, biomedicine, and precision engineering. Meanwhile, titanium alloys are difficult to machine and passivate readily. Electrochemical grinding (ECG) is an ideal technology for the efficient–precise machining of titanium alloys. In the ECG process of titanium alloys, the common approach of applying high voltage and active electrolytes to achieve high efficiency of material removal will lead to serious stray corrosion, and the time utilized for the subsequent finishing will be extended greatly. Therefore, the application of ECG in the field of high efficiency and precision machining of titanium alloys is limited. In order to address the aforementioned issues, the present study proposed an efficient–precise continuous ECG (E-P-C-ECG) process for Ti–6Al–4V applying high-pulsed voltage with an optimized duty cycle and low DC voltage in the efficient ECG stage and precise ECG stage, respectively, without changing the grinding wheel. According to the result of the passivation properties tests, the ideal electrolyte was selected. Optimization of the process parameters was implemented experimentally to improve the processing efficiency and precision of ECG of Ti–6Al–4V. Utilizing the process advantages of the proposed process, a thin-walled structure of Ti–6Al–4V was obtained with high efficiency and precision. Compared to the conventional mechanical grinding process, the compressive residual stress of the machined surface and the processing time were reduced by 90.5% and 63.3% respectively, and both the surface roughness and tool wear were obviously improved.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Investigation of the Efficient–Precise Continuous Electrochemical Grinding Process of Ti–6Al–4V

Yang,

Ming,

Niu

et al. 2024

Materials

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“…During the machining process, the anode is eroded in ionic form. [1,2] Theoretically, ECMM can achieve nanometer-level machining accuracy and is an ideal method for processing high-precision micro-parts, difficult-to-machine materials, and complex-shaped structures. It has broad application prospects in high-tech fields such as micro-robotics, MEMS, aerospace technology, and military industry.…”

Section: Introductionmentioning

confidence: 99%

Development of Nanosecond Spike Pulse Power Supply for Electrochemical Micromachining

Zhao

Zou²,

Ren³

et al. 2023

Preprint

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The use of pulse voltage can greatly improve the precision of electrochemical microfabrication, and the narrower the pulse width of the applied pulse voltage signal, the higher the machining precision. However, the commonly used chopper circuit topology of pulse power supplies is limited by the maximum switching frequency of the field-effect transistor. To address this problem, this paper proposes a nanosecond pulse electrochemical micromachining power supply based on a differential circuit. The power supply uses the STM32F103C8T6 microcontroller as the control core to output high-performance rectangular waves through a DDS device. After differential, rectification, filtering, and power amplification processing, stable, frequency, amplitude, and pulse width adjustable spike pulse voltage signals are obtained. By establishing a system mathematical model and optimizing the time constant of the differential circuit, theoretically, the sub-nanosecond pulse width can be obtained. Prototype performance tests show that the power supply has a maximum frequency of 20MHz, a minimum pulse width of 1.8ns, and a maximum peak voltage of 10V. By using this power supply for microhole electrochemical machining experiments, nanometer-level machining precision has been achieved. Compared with the power supply reported in the literature, the designed spike pulse power supply has a narrower pulse width and better waveform performance, thereby improving the precision and localization of electrochemical micromachining.

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“…ECM is used as a high-priority machining tool because of its specific advantages, such as minor tool wear, mechanical forceless machining, no heat-affected zones, high surface quality, low roughness, and stressfree surface products. ECM is the reverse process of electroplating and can machine any hard materials or complicated shapes [1]. In ECM, the workpiece and tool are connected with the anodic pole and the cathodic pole of the electrochemical circuit, respectively, and the electrolyte is pumped through the inter-electrode gap (IEG) between the tool and the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Meta-Heuristic Technique-Based Parametric Optimization for Electrochemical Machining of Monel 400 Alloys to Investigate the Material Removal Rate and the Sludge

Nagarajan¹,

Ayyappan²,

Kumar

et al. 2022

Applied Sciences

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Electrochemical machining (ECM) is a preferred advanced machining process for machining Monel 400 alloys. During the machining, the toxic nickel hydroxides in the sludge are formed. Therefore, it becomes necessary to determine the optimum ECM process parameters that minimize the nickel presence (NP) emission in the sludge while maximizing the material removal rate (MRR). In this investigation, the predominant ECM process parameters, such as the applied voltage, flow rate, and electrolyte concentration, were controlled to study their effect on the performance measures (i.e., MRR and NP). A meta-heuristic algorithm, the grey wolf optimizer (GWO), was used for the multi-objective optimization of the process parameters for ECM, and its results were compared with the moth-flame optimization (MFO) and particle swarm optimization (PSO) algorithms. It was observed from the surface, main, and interaction plots of this experimentation that all the process variables influenced the objectives significantly. The TOPSIS algorithm was employed to convert multiple objectives into a single objective used in meta-heuristic algorithms. In the convergence plot for the MRR model, the PSO algorithm converged very quickly in 10 iterations, while GWO and MFO took 14 and 64 iterations, respectively. In the case of the NP model, the PSO tool took only 6 iterations to converge, whereas MFO and GWO took 48 and 88 iterations, respectively. However, both MFO and GWO obtained the same solutions of EC = 132.014 g/L, V = 2406 V, and FR = 2.8455 L/min with the best conflicting performances (i.e., MRR = 0.242 g/min and NP = 57.7202 PPM). Hence, it is confirmed that these metaheuristic algorithms of MFO and GWO are more suitable for finding the optimum process parameters for machining Monel 400 alloys with ECM. This work explores a greater scope for the ECM process with better machining performance.

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Selected Aspects of Electrochemical Micromachining Technology Development

Cited by 13 publications

References 25 publications

An Investigation of the Efficient–Precise Continuous Electrochemical Grinding Process of Ti–6Al–4V

An Investigation of the Efficient–Precise Continuous Electrochemical Grinding Process of Ti–6Al–4V

Development of Nanosecond Spike Pulse Power Supply for Electrochemical Micromachining

Meta-Heuristic Technique-Based Parametric Optimization for Electrochemical Machining of Monel 400 Alloys to Investigate the Material Removal Rate and the Sludge

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