Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Patel, Divyansh Singh; Sharma, Vyom; Jain, V. K.; Ramkumar, J.

doi:10.1149/1945-7111/abf4e9

Cited by 9 publications

(5 citation statements)

References 38 publications

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“…Positioning the cathode at the bottom of the electrolyte chamber reduces the edge effect and concentration of electric charge at the edge. 43 The setup is illustrated in Fig. 6.…”

Section: Hypotheses For the Tool Damagesmentioning

confidence: 99%

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Ghasemiansafaei,

Schaefer,

Hall

et al. 2023

J. Electrochem. Soc.

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Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials. The contactless nature of ECM and anodic dissolution of the workpiece propound no tool ablation. Nevertheless, in a few studies, tool damages, namely the formation of pits and geometrical changes, have been observed, which is the investigative goal of this work. This study considers three hypotheses to investigate tool changes during pulsed electrochemical machining (PECM) which are hydrogen embrittlement, cavitation erosion, and cathodic corrosion. A systematic study of monitoring possible tool (1.4112 martensitic stainless steel) changes during ECM and PECM in aqueous NaNO3 electrolyte is performed. Experimental results of this study show that hydrogen embrittlement and cavitation erosion are not the reason for causing changes in the tool. Cathodic corrosion might be the reason for the changes in the tool in this study; however, more investigation is needed. The approach in this study is investigating the microstructure of the tool regarding different aspects before and after ECM and PECM, as the microstructure stores information regarding phenomena occurring during any process.

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“…Positioning the cathode at the bottom of the electrolyte chamber reduces the edge effect and concentration of electric charge at the edge. 43 The setup is illustrated in Fig. 6.…”

Section: Hypotheses For the Tool Damagesmentioning

confidence: 99%

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Ghasemiansafaei,

Schaefer,

Hall

et al. 2023

J. Electrochem. Soc.

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“…This method is also called as direct-write method , which can be used for machining micro-dimples, micro-channels and micro-pillars on flat surfaces. [27][28][29] Figure 2 illustrates the methodologies of mask-less single tool-based texturing.…”

Section: Mask-less Electrochemical Micro-texturingmentioning

confidence: 99%

“…25,113 • Tool-wear mechanism. 27,115 • Material-removal mechanism. 30,118 A good amount of work is carried out in this field.…”

Section: Implementation Of Molecular Dynamics Simulationmentioning

confidence: 99%

Micro-machining: An overview (Part II)

Jain

Patel

Ramkumar

et al. 2021

Journal of Micromanufacturing

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This article on ‘Micro-machining: An Overview (Part II)’ is in continuation to ‘Micro-machining: An Overview (Part I)’ published in this journal ( Journal of Micromanufacturing). It consists of four parts, namely, electrochemical micro-texturing, electrochemical spark micro-machining, molecular dynamics simulation and sustainability issues of micro-machining processes. Electrochemical micro-texturing (ECMTex) deals with various techniques developed for micro-texturing on different types of workpiece-surfaces, namely, flat, curved and free-form surfaces. Here, basically two categories of techniques have been reviewed, namely, with mask and without mask. It also deals with ‘single point tool micro-texturing’ which turns out to be a single-step technique requiring minimum time, but the accuracy and repeatability obtained after micro-texturing need to be critically analysed. For mass production, one needs to go for sinking kind of ECMTex processes. Electrochemical spark micro-machining (ECSMM) is an interesting hybrid (ECM+EDM) process which can be applied for electrically conducting as well as electrically non-conducting materials. However, the work reported in this article deals only with the electrically non-conducting materials for which this process was initially developed. This process has a lot of potential for theoretical work to be done. In this article, two theories of sparking/discharging have been briefly mentioned: single bubble discharging/sparking and single surface discharging. It also dicusses its applications for different types of electrically non-conducting materials. Molecular dynamics simulation (MDS) of micro-/nano-machining processes is very important, but it is very cumbersome to understand at atomic/molecular scale. In these processes, the material behaviour at micro-/nano-level machining is completely different as compared to bulk-machining (macro-machining) processes. Hence, some fundamentals of MDS have been discussed. It just gives the idea of available techniques, softwares and models for different types of processes. However, there is the need of further research work to be done for clearly understanding the MDS of micro-/nano-machining. In the end, the sustainability of micro-machining issues have been discussed, mainly based on the energy consumption per unit mass of production. It is concluded that the advanced micro-manufacturing processes are highly energy-intensive processes, and they need further studies to be done for making them more suitable from sustainability point of view. At the end of each section, some potential areas of research for enhancing the accuracy and repeatability, and minimising the production time of each process have been discussed.

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“…Electrochemical machining (ECM) is an effective and well-established technology for shaping complex machinery pieces [1] and for microfabrication [2,3], using different substrates such as titanium [4], copper [5] nickel alloys [6,7], stainless steel [8,9], and refractory materials [10]. Another advantage of ECM is the absence of any residual stress, plastic deformation, fatigue, or burrs, and the low roughness of the surface, due to the absence of physical contact between the workpiece and the ECM electrode [10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Sludge Reduction and Surface Investigation in Electrochemical Machining by Complexing and Reducing Agents

Cercal,

de Alvarenga,

Vidotti

2023

Processes

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Electrochemical machining (ECM) is widely applied to manufacture parts with complex geometries, used in electronic components and the automotive, military, and aeronautics industries. These parts have a surface shaped by controlled anodic dissolution at high current density levels, using a neutral solution of inorganic salts (i.e., NaCl or NaNO3) as the electrolyte. Such conditions generate a high amount of sludge that deposits onto the surfaces of equipment, devices, cathodes, and working pieces, requiring daily and complicated sludge management during the series production in the industry. Thus, the main goal of the present work is to propose a simple way to reduce sludge generation in the ECM industrial process. To do so, complexing (EDTA) or reducing (ascorbic acid) agents were added to the electrolyte composition, creating parallel reactions to keep the metallic ions from precipitating. The complexing agent EDTA resulted in a 30% reduction in sludge mass, using an alkaline solution (pH > 10.0). The reducing agent, ascorbic acid, resulted in a 90% reduction in sludge mass, using an acidic solution (pH < 5.0). This sludge reduction has the potential to contribute significantly to increasing equipment, devices, and cathode lifetime, as well as reducing costs associated with centrifuge or filter maintenance (sludge removal from electrolyte) and increasing the productivity of industrial ECM processes.

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Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Cited by 9 publications

References 38 publications

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Micro-machining: An overview (Part II)

Sludge Reduction and Surface Investigation in Electrochemical Machining by Complexing and Reducing Agents

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