Visualization of electro-physical and chemical machining processes

Kunieda, Masanori; Overmeyer, Ludger; Klink, Andreas

doi:10.1016/j.cirp.2019.05.011

Cited by 25 publications

(8 citation statements)

References 114 publications

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“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 µm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [5]; (2) analysis and modification of electric current distribution on the workpiece surface [6,7]; (3) selection of optimal composition of electrolyte [8]; (4) technology development, i.e., simulation of machining or the tool shape/path design [9];…”

Section: Introductionmentioning

confidence: 99%

“…It is related to selection of optimal conditions of dissolution under the small interelectrode gap (<100 μm). The scope of the conducted research includes especially: (1) explanation of the phenomena in interelectrode gap during dissolution [ 5 ]; (2) analysis and modification of electric current distribution on the workpiece surface [ 6 , 7 ]; (3) selection of optimal composition of electrolyte [ 8 ]; (4) technology development, i.e., simulation of machining or the tool shape/path design [ 9 ]; (5) development of power suppliers and gap control strategy [ 10 ]; and (6) improvement of machining conditions by additional energy sources (i.e., ultrasonic vibrations [ 11 , 12 ]) or (7) integration with other technologies [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

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Selected Aspects of Electrochemical Micromachining Technology Development

et al. 2021

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The paper focuses on the fundamentals of electrochemical machining technology de-elopement with special attention to applications for micromachining. In this method, a material is removed during an anodic electrochemical dissolution. The method has a number of features which make it attractive technology for shaping parts with geometrical features in range of micrometres. The paper is divided into two parts. The first one covers discussion on: general characteristics of electrochemical machining, phenomena in the gap, problems resulting from scaling down the process and electrochemical micromachining processes and variants. The second part consists of synthetic overview of the authors’ research on localization of pulse electrochemical micromachining process and case studies connected with application of this method with use of universal cylindrical electrode-tool for shaping cavities in 1.4301 stainless steel. The latter application was conducted in two following variants: electrochemical contour milling and shaping carried out with sidewall surface of rotating tool. In both cases, the obtained shape is a function of electrode tool trajectory. Selection of adequate machining strategy allows to obtain desired shape and quality.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Selected Aspects of Electrochemical Micromachining Technology Development

et al. 2021

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“…Ehle et al studied microstructural characterizations of surface zones to gain reliable information on the cooling rate in sinking EDM [11]. Kunieda et al visualized spatio-temporal phenomena in electro physical and chemical processes in order to understand machining mechanisms and to achieve a technological breakthrough [12]. Although some mechanism simulations of nano EDM with the pulsewidth even narrowing to picosecond scale have been carried out [13][14][15], real discharging experiments on machining effect of nanosecond pulsewidth are still scarce.…”

Section: Introductionmentioning

confidence: 99%

Ns-pulsewidth pulsed power supply by regulating electrical parameters for AFM nano EDM of nm-removal-resolution

Ran

Tong

2021

Nanotechnology

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Nano electro discharge machining (nano EDM), as a frontier processing method in the research stage of exploration, has an important application prospect in the machining of metal and alloy materials for achieving nanoscale removal resolution. A pulsed power supply used in nano EDM is expected to limit a single pulse energy to nJ order of magnitude for improving the removal resolution of single pulsed discharge even to nanoscale. One developing direction is to decrease pulsewidth of the pulsed power supply. Conventional pulsed power supplies hardly output a single pulse and continuous pulses with nanosecond (ns) pulsewidth, resulting in too large single pulsed energy of μJ order of magnitude usually. In this research, a novel pulsed power supply is designed for realizing the ns-pulsewidth with controllable pulsewidth and peak voltage. The key novelty lies in a cascaded circuit with two triodes working in the state of ultra-fast avalanche conduction, where pF capacitors are applied to adjust the pulsewidth and pulsed energy precisely. Performance tests verified that a single pulse of 5 ns pulsewidth or continuous pulses up to 9 MHz can be outputted. Furthermore, nano EDM experiments of single pulsed discharge are carried out under the conditions of nanometer (nm) discharge gap and nm-tip tool electrode based on an atomic force microscope (AFM) system. The special results are achieved: a single pulsed energy can reach down to 1.75 nJ by outputting a pulsewidth of 10 ns, and a nano-EDM crater is only about 182 nm in diameter with regular shape and little recasting. Those results verify the possibility of AFM-tip-based nano EDM for machining nanostructures.

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“…Evaluation of physical phenomena close to the machining gap is critical for understanding the underlying process mechanisms especially in hybrid processes. A better visualization of process in the machining zone 16 helps in achieving deterministic material removal leading to high quality products. Some attempts have been made by Kunieda et al 17 to visualize inter-electrode gap phenomena using a transparent electrode.…”

mentioning

confidence: 99%

Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

Saxena

Chen

Vetrano

et al. 2020

Sci Rep

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A tool-based hybrid laser-electrochemical micromachining process involves concurrent application of two process energies i.e. electrochemical and laser in the same machining zone by means of a hybrid tool which serves as an ECM tool as well as a multimode waveguide. It is a relatively novel process finding applications in defect-free machining of difficult-to-cut materials without affecting their microstructure. In order to understand the physical phenomena occurring during this process, in-situ observations are required. Therefore, in this work, a real time observation was carried out of a novel tool-based hybrid laser electrochemical micromachining process. A combination of high-speed imaging and Large Scale Particle Image Velocimetry (LSPIV) was used to visualize the tool-based hybrid laser-ECM process in real time. It also allowed to carry out experimental investigations on the by-products and bubble generation which have a direct effect on process performance in terms of accuracy and efficiency. The real-time on-machine observations are unique of its kind and they will facilitate the understanding of underlying mechanisms governing this hybrid laser-electrochemical micromachining process. This will ultimately help in improving the quality of parts manufactured. This research is also a step forward towards making these physics-based hybrid processes deterministic by employing high-speed imaging in a closed loop control.

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Visualization of electro-physical and chemical machining processes

Cited by 25 publications

References 114 publications

Selected Aspects of Electrochemical Micromachining Technology Development

Selected Aspects of Electrochemical Micromachining Technology Development

Ns-pulsewidth pulsed power supply by regulating electrical parameters for AFM nano EDM of nm-removal-resolution

Real-time on-machine observations close to interelectrode gap in a tool-based hybrid laser-electrochemical micromachining process

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