The characterization of electrochemically machined surfaces

Mileham, A R; Harvey, S. J.; Stout, K.J.

doi:10.1016/0043-1648(86)90265-6

Cited by 75 publications

(42 citation statements)

References 6 publications

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“…It is suitable for plastic or press dies, wire-drawing dies and optical parts [13]. The experimental results of Mileham et al showed that the quality of the machined surface will be influenced by current density, flow rate of electrolyte and the gap width [14]. High-density pulsed direct current improves the precision of workpieces.…”

Section: Introductionmentioning

confidence: 99%

Electropolishing of cylindrical workpiece of tool materials using disc-form electrodes

Hocheng

2003

Journal of Materials Processing Technology

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This research presents a new application of electropolishing using a low-cost disc-form electrode offering fast improvement of the surface roughness of SKD61. It requires no expensive special-purpose equipment or heavy material removal as conventional electrochemical machining does, and it also avoids the complex pre-polishing of the workpiece before the electropolishing. Round bars or round tubes produced by traditional turning, drawing, form rolling, or extrusion, can be successively electropolished using the designed disc-form electrodes. Five electrode designs are discussed. The experimental parameters include rotational speed of workpiece, electrical current rating and pulse period, electrode geometry, and electrode feed rate. Thinner disc and larger disc taper angle are associated with larger discharge space for the electrode, thus the polishing is more effective. A smaller end radius of the disc electrode produces higher current density and provides faster feed rate and a better polishing effect. A disc with discharge flute performs better, and larger flute back rake angle, side rake angle, wider flute, and deeper flute depth are also advantageous. Although the use of pulsed current slightly outperforms the fluted electrode using continuous current, it sacrifices both machining time and cost. The best electrode design is identified. A guideline for the design of electrodes is provided based on the experimental results.

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Section: Introductionmentioning

confidence: 99%

Electropolishing of cylindrical workpiece of tool materials using disc-form electrodes

Hocheng

2003

Journal of Materials Processing Technology

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“…According to the experimental results of Mileham and others, the use of changing machining conditions will directly influence the quality of machined appearances. The experimental results of Mileham et al showed the quality of the machined surface will be influenced by the current density, flow rate of electrolyte, and the gap width [36]. Datta and Shenoy showed that the gap width between electrode and workpiece directly influences the current condition and the discharge dregs of the electrolyte [37].…”

Section: The Removal Rate Of Depthmentioning

confidence: 98%

Electrochemical Machining

Pa¹,

Hocheng²

2012

Advanced Analysis of Nontraditional Machining

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Electrochemical machining has attracted increasing attention for micro-machining applications. The first section discusses a process to erode a hole of hundreds of microns diameter in a metal surface using a moving electrode. The discussion provides a method to predict the enlargement of the produced hole and to taper under the applied machining conditions. A computational model illustrates how the machined profile develops over time and as the electrode gap changes. The analysis is based on Faraday's laws of electrolysis and the mathematical integral describing a tool. The effectiveness of the model is tested by experiments that apply several electrode movement schemes.This chapter discusses the surface roughness of several common die materials produced by traditional machining, whereby the internal and external cylindrical surface are electropolished by different electrode designs. Electropolishing efficiency of die materials and parts should be high to improve surface roughness in the shortest amount of time possible, thereby reducing surface residual stresses. The study aims to identify an optimal electrode design, which will help broaden electromachining applications in the future. For electropolishing of internal holes, completely inserted feeding electrodes are supplied with both continuous and pulsed direct current. In the external electropolishing studies, we consider the design of the turning tool electrode, arrowhead electrode, ring-form electrode, and disc-form electrode. For internal electropolishing, an electrode featuring a helix discharge flute performs better than that without a flute or with a straight flute. The borer type electrode performs better an electrode with a lip on the leading edge. Pulsed direct current can improve the polishing, but the machining time and

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“…Datta and Landolt (1981) showed that the gap width between the electrode and workpiece directly influences the current condition and the discharge dreg of the electrolyte. The experimental results of Mileham et al (1986) proved that the quality of the machined surface would be influenced by factors including current density, flow rate of electrolyte and the gap width in the ECM. Bejar and Gutierrez (1983) used NaNO 3 as an electrolyte and changed the machining gap width as well as the concentration of electrolyte to investigate the influence on current efficiency.…”

Section: Introductionmentioning

confidence: 94%

An effective microsystem by design of a twin-plate tool for precision removal

2010

Microsyst Technol

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The low yield of ITO thin film deposition is an important factor in semiconductor production. An effective microsystem with economic viability that uses micro electroremoval as a reclaim process was developed to remove the defective ITO nanostructure coatings from the optical PET surfaces of digital paper. By establishing the reclaim process using the ultra-precise removal of the nanostructure coatings, the optoelectronic semiconductor industry can effectively reclaim defective products, minimizing both production costs and pollution. In the current experiment, a large twin-plate cathode with a small gapwidth between the cathode and the workpiece takes less time for the same amount of ITO removal. A small end radius of the cathode combines with enough electric power to drive fast machining. Pulsed direct current can improve the effect of dreg discharge, and it is advantageous to associate the workpiece with the fast feed rate. However, this improvement can increase the current rating. A high rotational speed of the electrodes, a higher temperature, or a large flow rate of the electrolyte corresponds to a higher removal rate for the ITO nanostructure. The micro electroremoval requires only a short period of time to remove the ITO thin film coatings easily and cleanly.

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The characterization of electrochemically machined surfaces

Cited by 75 publications

References 6 publications

Electropolishing of cylindrical workpiece of tool materials using disc-form electrodes

Electropolishing of cylindrical workpiece of tool materials using disc-form electrodes

Electrochemical Machining

An effective microsystem by design of a twin-plate tool for precision removal

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