Study on the wire electrochemical groove turning process

Abstract

In this study a copper wire is proposed as a tool electrode in electrochemical groove turning process (WECGT). The working parameters, namely, radial feed rate, wire diameter, and rotational speed are investigated to study the performance criteria via MRR, groove width, and roundness error. An experimental study is presented through performing series of designed experiments. Key features of a WECGT setup that was designed and developed incorporating several unique features are also highlighted. The experimental results are statistically analyzed and mathematically modeled through response surface methodology (RSM). The mathematical model adequacies are checked using analysis of variance (ANOVA). Furthermore, optimal combination of working parameters has been evaluated to maximize MRR and minimize roundness error. The results reveal that using wire as an electrode in electrochemical turning instead of using a profiled tool proved its powerfulness to produce circular grooves. The results also demonstrate that the groove width has greatly increased by increasing the wire diameter, while it is decreased by increasing both the radial feed rate and rotational speed. Lower roundness errors are obtained by increasing both radial feed rate and wire diameter. The optimum combination of parameters setting is: radial feed rate of 0.08 mm min -1, wire diameter of 2.3 mm, and rotational speed of 578 rpm.

Flow field design and experimental study of electrochemical machining using thin hollow cathodes

“…Xu et al 24 studied vibration-assisted wire electrochemical micromachining of array micro-tools, and they indicated that large amplitudes and high speeds of cathode vibration and large amplitudes and high frequencies of anode vibration could reduce the edge radius and improve the homogeneity of the slit width. Kim et al 25 and El-Taweel and Gouda 26 studied on the effect of micro-wire cathode, high-frequency pulse voltage, feed rate, and electrolyte on the ECM. Because the diameter of the wire is small, the rigidity is poor and the cut slot is narrow.…”

Experimental and analytical investigations into wire electrochemical micro turning

“…The study on wire EC groove-making process was also proposed, and effects of input parameters on MRR, groove width, and roundness error were studied by El-Taweel and Gouda. 10 Wang et al 11 fabricated micro annular grooves on the cylindrical surface of aluminium alloy using wire EC micromachining (wire ECMM). The dependency of groove width on applied potential, pulse frequency and workpiece rotational speed was studied.…”

Study of surface roughness in wire electrochemical micro machining

“…Electrochemical micro machining (EMM) appears to be promising as a future micro machining technique because it offers several advantages, which include no tool wear, stress-free, high material removal rates, better precision and control, and rapid machining rates. It is reliable, flexible and environmentally acceptable, and it also permits proper machining of chemically resistant materials such as superalloys (El-Taweel and Gouda, 2011) and stainless steel (Kim et al, 2005). Another advantage of EMM is that hard metals can easily be machined, regardless of the mechanical properties of a workpiece, and smooth and burrfree surfaces are produced (Zhu et al, 2007).…”