The effects of magnetic field and ethanol addition on the electrochemical discharge machining

Lin, Ming‐Yuan; Tsai, Te‐Hui; Hourng, Lih‐Wu; Wang, Wei-kai

doi:10.1007/s00170-019-04413-7

Cited by 12 publications

(3 citation statements)

References 15 publications

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“…The gas film state dramatically impacts the processing outcome, and by limiting it, the processing range and accuracy may be enhanced (Lin et al, 2019) EMM performance is studied using WC…”

Section: Ecdmmentioning

confidence: 99%

A Review on Recent Achievements and Challenges in Electrochemical Machining of Tungsten Carbide

Asmael,

Memarzadeh

2023

AAES

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Electrochemical machining (ECM) is a modern, unconventional manufacturing technique that uses the electrochemical dissolution of metal to produce pieces with a predetermined shape, dimensions, and surface polish. Tungsten carbide (WC) is used in many fields and applications due to its high wear resistance and hardness. WC is used in cutting tools, mining and drilling equipment, wear parts, industrial machinery, aerospace and defence components, and medical equipment. It gives a workpiece a particular shape and number of boreholes, removes a damaged outer coat, and eliminates surface roughness. Though the ECM of WC is fraught with difficulties and obstacles, altering the electrolytes and refining the technological equipment and process of the ECM of WC can help improve machining accuracy and stability. In the current study, we examined the ECM of WC and compiled a reliable database from reliable sources using the keywords "electrochemical machining" and "tungsten carbide". Research papers constitute the majority of these publications. It was discussed how WC behaves anodically as it applies to ECM, which experiments were conducted with various electrolytes, and how they performed. Several ECM modes have been considered, and each mode has been evaluated in detail for challenges and gaps.

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“…The gas film state dramatically impacts the processing outcome, and by limiting it, the processing range and accuracy may be enhanced (Lin et al, 2019) EMM performance is studied using WC…”

Section: Ecdmmentioning

confidence: 99%

A Review on Recent Achievements and Challenges in Electrochemical Machining of Tungsten Carbide

Asmael,

Memarzadeh

2023

AAES

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“…Magnetic fields as low as 0.24 T were capable of producing good quality entrance holes. The impact of including an ethanol and magnetic field during the ECSM processing of quartz was examined by Lin et al (2019). Singh et al (2020) proposed rotary mode-electrochemical discharge drilling (RM-ECDD) for machining of a metal matrix composite (Al-6063 SiC p ).…”

Section: Introductionmentioning

confidence: 99%

Parametric analysis and optimization of magnetic field-assisted electrochemical spark drilling (MF-ECSD)

Singh

2023

Eng. Res. Express

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Electrochemical spark machining (ECSM) is gaining tremendous recognition in the research fraternity due to its ability to machine non-conductive materials and hybridize with other forms of energy (ultrasonic and magnetic). In the present work, ECSM has been hybridized with magnetic energy by adding an electromagnetic unit in the in-house developed setup of magnetic field-assisted electrochemical spark drilling (MF-ECSD), to improve the material removal rate (MRR), machining depth (MD) and overcut (OC) of sodalime glass. Due to the addition of electromagnetic component into the setup, magnetic field of varying strengths were generated near the machining zone. Effect of magnetic field on size of bubbles and in exclusion of fragments from the machining region was examined during experimentations. This study also concentrated on the effect of selected input factors such as applied voltage, NaOH concentration, tool rotational speed (TRS) and magnetic field intensity (MFI) on MRR, MD, and OC. The regression model was developed based on experimental results and further analyzed to predict the pattern of responses beyond the selected range of parameters. The experimental and analytical results were in good corroboration and all the factors were found significant for enhancing the responses. Later, the Desirability Function technique for multi-objective optimization was applied to maximize MRR and MD and minimize OC which yielded an ideal value of 40.10 V, 30 wt%, 90 rpm, and 0 Tesla with overall desirability of 0.7238.

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“…Wüthrich et al [19] introduced a soap solution into the electrolyte to reduce the thickness of the gas film and finally improved the machining repeatability. Lin et al [20] added the ethanol to the electrolyte and applied a magnetic field to explore the machining accuracy on glass. Experimental results showed that the electrolyte flow and bubbles around the electrode were relatively stable under the magnetohydrodynamic effect, and the roundness of the machined hole was significantly improved and the hole taper improved by 30%.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of the Machining Characteristics in Graphite-Powder-Mixed Electrochemical Discharge Machining of Microholes in Glass

Tang,

Yao,

Zhang

et al. 2023

Micromachines

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The effect of graphite powder on the machining characteristics in graphite-powder-mixed electrochemical discharge machining of microholes was still not clear. How the discharge mechanism changed with the addition of graphite powder into the electrolyte, which further led to changes in the morphology of the machined holes, remained to be revealed. In this study, a series of microhole machining experiments were conducted in glass. Comparisons of the discharge energy, microhole entrance diameter, hole taper, and tool electrode morphology after machining were made when machining in the electrolytes with and without graphite powder. Experimental results revealed that there were a lot of small pulse currents distributed on the current waveform when machining with the graphite-powder-mixed electrolyte. The average discharge energy of the small pulse current was 2.8 times as much as that of the general electrochemical discharge. After introducing graphite powder into the electrolyte, the entrance diameter of the hole became larger when the hole depth was deeper than 200 μm. The HAZ width increased with increasing hole depth at the voltage of 37–41 V, while it decreased at the voltage of 43 V. A reduction in hole taper angle with a range of 0.5° to 2.3° was achieved. In addition, after machining in electrolytes with and without graphite powder, the tool electrode surfaces showed different morphologies due to different discharges.

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The effects of magnetic field and ethanol addition on the electrochemical discharge machining

Cited by 12 publications

References 15 publications

A Review on Recent Achievements and Challenges in Electrochemical Machining of Tungsten Carbide

A Review on Recent Achievements and Challenges in Electrochemical Machining of Tungsten Carbide

Parametric analysis and optimization of magnetic field-assisted electrochemical spark drilling (MF-ECSD)

Experimental Investigation of the Machining Characteristics in Graphite-Powder-Mixed Electrochemical Discharge Machining of Microholes in Glass

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