The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Zhang, Xinmin; Song, Xudong; Ming, Pingmei; Li, Xinchao; Zeng, Yongbin; Cai, Jiejin

doi:10.3390/mi10060404

Cited by 18 publications

(13 citation statements)

References 25 publications

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“…Zhang et al performed machining by orienting the jet in a horizontal position, vertically upwards position, and vertically downwards position. 10 It is concluded in this study that the horizontal orientation of electrolyte jet is most suitable for machining accurate micro holes with excellent surface quality. The results in the other two orientations were not favorable.…”

mentioning

confidence: 81%

Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Patel

Sharma

Jain

et al. 2021

J. Electrochem. Soc.

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Electrochemical micromachining (ECMM) is a promising and economical process that can machine hard-to-machine metals with high material removal rate and good surface integrity. In this work, an attempt has been made to develop a novel atomized electrolyte flushing technique to enhance mass transport. An atomizer is employed for supplying pressurized micro-droplets of electrolyte on the workpiece surface which leads to the formation of a thin and mobile fluid film. This thin film of electrolyte, moving with a high velocity helps in overcoming the problems associated with jet flushing such as radial overcut, stray corrosion, and usage of a large volume of electrolyte for machining. Numerical simulations of atomized electrolyte-based ECMM are carried out by considering a thin electrolyte film in the interelectrode gap to predict the evolution of anode profile on SS304 workpiece. Experimental observations suggest that in comparison with jet electrolyte flushing, the average dimple diameter reduced by 13% and the average dimple depth increased by 52.3% in case of atomized electrolyte flushing at an applied potential of 6 V and electrolyte conductivity of 1.5 S m−1. It is concluded that the consumption of electrolyte decreases significantly and the localization of dissolution zone improves which ultimately enhances machining performance.

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mentioning

confidence: 81%

Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Patel

Sharma

Jain

et al. 2021

J. Electrochem. Soc.

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“…With its help, most of the current is constrained at the jet center and a Gaussian-type pit mark is formed on the surface after machining. 19,22,24,26,32 The mathematical model of the Jet-ECM surface flattening process.-A mathematical model is needed to determine the parameters such as nozzle traveling path and moving speeds to flat the workpiece with the Jet-ECM process efficiently. To establish this model, the material removal function (m(r s )), a mathematical function to describe the MRR of Jet-ECM, is required.…”

Section: Mechanism and Mathematical Modelmentioning

confidence: 99%

“…19,23,24 Based on the high machining flexibility of Jet-ECM 25 and the principle of computer-controlled optical surfacing (CCOS), through controlling the trajectory and dwelling time of the nozzle, the amount of material removal at different positions of the workpiece can be manipulated. [26][27][28] Therefore, Jet-ECM can manufacture flat or wavy surfaces 19 as well as various kinds of structures on the workpiece such as pits, 26,29 grooves, 30,31 or other complex structures 32,33 for different industrial applications. In previous studies, Natsu et al (2007) 32 proposed an algorithm to obtain the nozzle traveling path and scanning speed to generate a complicated groove (diameter: 2 mm, depth: 100 μm) by superimposing simple patterns.…”

mentioning

confidence: 99%

Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

Wang

Yan

Zhou

et al. 2020

J. Electrochem. Soc.

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Ultra-flat and ultra-smooth copper (Cu) surfaces are widely used as optical mirrors, heat sinks, and substrates for functional material growth. Traditional polishing methods that rely on abrasive particles are easy to induce mechanical defects such as abrasives embedding and scratches on surfaces. A new stress-free machining process is proposed in this research to fabricate an ultra-flat and ultra-smooth Cu surface by combining jet electrochemical machining (Jet-ECM) and electrochemical polishing (ECP). With the accurate manipulating of material removal rate (MRR) and planning of nozzle trajectory, an ultra-flat surface can be obtained efficiently in the Jet-ECM process. The surface roughness of the workpiece can be further improved by ECP with the same electrolyte used in the Jet-ECM process. The results show that the surface peak-to-valley (PV) value which indicated the surface form error of the Cu surface was reduced from 4.4 μm to 1.7 μm and the surface roughness Sa was reduced from 70.3 nm to 13.5 nm. The combination of Jet-ECM and ECP which share the same electrolyte and apparatus can improve the surface flatness and roughness significantly. This study improves the machining accuracy of stress-free machining methods and has great implications for the further understanding of the electrochemical removal mechanism.

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“…ECJM employs a nozzle-shaped tool that allows the flow of electrolyte with better localization of the surface treatment compared to conventional ECM. By properly controlling the trajectory of the nozzle, ECJM allows flat and complex surfaces to be processed, generating a large variety of surface features [19] including holes, dimples and grooves. In particular, the fabrication of textures with ECJM produces hierarchical topographies characterized by features on multiple length scales, ranging from hundreds of nanometres to tens of microns depending on the processing conditions [17].…”

Section: Introductionmentioning

confidence: 99%

A novel approach for detecting undercuts within surface textures generated by Electrochemical Jet Machining (ECJM)

Lazzini¹,

Romoli²,

Kunieda³

2021

Surf. Topogr.: Metrol. Prop.

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The present study proposes a novel method for detecting micrometric undercuts (UCs) generated by electrochemical machining for the production of surfaces with tailored functionality. Two different algorithms for the detection of UCs based on two-dimensional topographic maps are tested. The first is a traditional approach based on definition of UCs in terms of surface orientation with respect to a reference direction. The second is an innovative alternative approach designed to reduce sensitivity to numerical effects that potentially lead to overestimation of the number of detected UCs. Electrochemical Jet Machining (ECJM) is used to texture SUS 316L specimens with the aim of producing a measurable surface with a representative number of micrometric UCs. Generated surface textures, comprising craters with diameters ranging from a few microns to tens of microns, are cross-sectioned and inspected with Scanning Electron Microscopy. The extracted profiles allow the novel method for detection of UCs to be efficiently tested and compared with the traditional approach. The number of UCs is found to decrease with increasing electrolyte jet scanning speed, while remarkable differences are revealed between the two calculation approaches at scanning speeds below 2 mm s−1.

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The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Cited by 18 publications

References 25 publications

Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Sustainable Electrochemical Micromachining Using Atomized Electrolyte Flushing

Preparation of Flat and Smooth Copper Surface by Jet Electrochemical Machining and Electrochemical Polishing

A novel approach for detecting undercuts within surface textures generated by Electrochemical Jet Machining (ECJM)

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