The Effects of Tool Electrode Size on Characteristics of Micro Electrochemical Machining
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Electrical Discharge Machining
Electrochemical Machining
Recently, additive manufacturing (AM) with selective laser melting (SLM) method using metal powder is attracting attention as a promising technique for producing various complex shapes efficiently. In this paper, we describe the application of the AM method to the fabrication of tool electrodes for Electrical Discharge Machining (EDM). The EDM properties of a copper electrode fabricated by the AM method (AM-Cu electrode) were investigated, and the applicability as a tool electrode for EDM was examined. Then, the AM-Cu electrode was applied to deep slot machining with a high aspect ratio, and its effectiveness was verified. As a result, we confirmed that the EDM properties of the AM-Cu tool electrode were similar to those of the conventional Cu tool electrode. Moreover, it was shown that using the AM-Cu tool electrode with microholes inside reduced the EDM processing time and significantly improved the machining accuracy compared with the case of using the conventional solid Cu tool electrode.
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Electrochemical machining (ECM) is a promising approach to manufacture micro textures on the metallic workpiece surface. However, due to the fluidity of the electrolyte, the undercutting and stray corrosion always exist on the processing surface which make the surface shape and integrity difficult to control. This paper proposed a new surface texturing processing method called ECM with electrolyte confined by absorption material (ECM-ECAM). During machining, the non-metallic absorption material is inserted between the cathodic tool and the anodic workpiece after absorbing the electrolyte. Since the flowing electrolyte is replaced with the electrolyte that is absorbed and confined in the absorption material, limitation of the electrolyte existing area and the machining area is realized. In this way, micro textures could be generated with an effective voltage applied between the cathode and the workpiece. The machining principle, designed and fabricated machining system and the machining results are presented in this paper.
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In the present study machining performance of a novel ABS P400 based EDM electrode is experimentally investigated. Three EDM parameters that is, current ( I), pulse on time ( T on ) and pulse off time ( T off ), each at three levels, are considered, and mild steel is machined using these electrodes according to the response surface methodology (RSM) based face-centred central composite design (FCCCD). Machining performances such as material removal rate ( MRR), tool wear rate ( TWR) and surface roughness ( SR) are measured. Experimental results are analysed using analysis of variance (ANOVA), response graphs and 3D surface plots. Current is found to be the dominating parameter for MRR, TWR and SR. The optimal combination of EDM parameter for multi-performance is determined using teaching-learning based optimization (TLBO) algorithm. The effectiveness of the new electrodes is established by comparing their machining performances with the already developed electrode at the same machining parameter setting. MRR resulting from the new electrode and also its TWR are found to be in good agreement with those of already produced electrodes. However, SR of the machined surface using new electrodes is found to be relatively higher.
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In the micro-electric discharge machining (μ-EDM), it is thought to be difficult to achieve nano-accuracy finishing because of its machining principle and severe electrode wear. Under such circumstance, this study aims to fabricate the micro-structures with high-accuracy by μ-EDM. In this report, the fabrication experiments of micro-grooves were conducted to the stainless workpieces with Cu-W fine electrodes to investigate the mechanism of the electrode wear that became important for three dimensional structure formation. Also, the coarse and fine planetary motion machining was proposed and performed to fabricate the layer structure. As a result, its effectiveness was confirmed.
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In this paper, we report on the co-operative control of a 5-DOF controlled magnetically-levitated (maglev) local actuator (MLA) combined with a conventional electrical discharge machine, which we developed as a means to increasing the electrical discharge machining (EDM) speed for small deep holes. The MLA enables the electrode to be rotated as well as to be rapidly positioned. Compared to conventional EDM without electrode rotation, the machining speeds in machining φ0.5×4mm and φ1×4mm through holes were increased by 125% and 337%, respectively, using the EDM machine combined with the MLA without electrode rotation ; while with electrode rotation, the co-operatively controlled combination increased the machining speed by a maximum of 343% in machining φ0.5×4mm through holes at 800rpm and 433% in machining φ1×4mm through holes at 600rpm.
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This paper describes development of a method for selective surface texturing using electrolyte jet machining. Electrolyte jet machining is an electrochemical machining method in which dissolution occurs selectively where the electrolyte jet hits the surface of the anode. This process is characterized by the ability to control the surface finish of the removed or added micro patterns by the current density in the electrolyte jet. Higher current density results in a mirror-like surface, while lower current density realizes significantly rough and complicated structures which are difficult to obtain with other machining processes.
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The electrode material is playing the very important role in the electrical discharge machining. Two kinds of electrode materials common used in EDM are compared and analyses similarities and differences in structure and physical characteristics. Combined with PcBN tool machining tests, from the electric discharge machining efficiency, electrode wear, tool surface quality, tool surface degenerating layer, machining results are in analysis and comparison, and then different electrode materials machining technics in electrical discharge machining process are summarized. Through the cutting tool electric discharge machining experiments, we can know that the graphite electrode easy to take shape, suits in the complex edge's cutting tool electric discharge machining, under the same electric discharge machining parameter condition, its processing efficiency must be higher than the copper electrode, but the electrode loses, the cutting tool surface quality and affect layer thickness are to be worse than the copper electrode.
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Abstract Silicon is the material that is most frequently utilized in the electronic industries because of its distinctive properties which encompasses from age resistance to high temperature stability. However, it is extremely challenging to machine silicon using conventional machining processes that employs traditional cutting force. As a result, non-conventional machining techniques have gained popularity and Electrical Discharge Machining (EDM) is one of the non-conventional machining techniques that has enormous potential in terms of machining silicon. However, the slow rate of material removal is the major drawback of machining silicon using EDM. This study seeks to investigate unique electrode designs and explore their efficacy in terms of improving material removal rate (MRR), reducing electrode or tool wear rate (TWR), and improving quality of the features machined by those electrodes. In this study, graphite electrodes with different arrays (1 × 4, 2 × 4 and 3 × 4) and leg heights (0.2” and 0.3” of electrode legs) were made using milling machine and were used in the die sinking EDM process to investigate the effects of heights and arrays on the material removal rate, tool wear rate and dimensional accuracy of the fabricated features keeping the EDM parameters constant. It has been observed that the increase of arrays of electrode legs results in shorter machining times per leg due to improve flushing conditions for both cases of electrode height. For lower arrays of electrode legs, smaller height (0.2″) performs better in terms of material removal rate. At 3 × 4 arrays of electrode, both cases of height of electrode show almost identical material removal rate. In case of dimensional accuracy, the quality of features improved with increased arrays of electrode legs for both leg heights (0.2” and 0.3″) of electrode. However, for overall accuracy of the features, height does not have significant effect as both performs quite similar. In this study, electrode wear rate is found negative due to carbon deposition on the graphite electrode. With the increased arrays of electrode legs, there is a decrease in carbon deposition per legs of electrode for both cases of electrode height. In terms of the effects of electrode leg height, each case of arrays performs quite alike.
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