Electrochemical Machining Multiple Slots of Bipolar Plates with Tool Vibration
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Electrochemical Machining
The characteristics of MEMS (micro-electro-mechanical system) are presented. Micro-machining technology, especially micro-USM (ultrasonic machining) and micro ECM (electrochemical machining) are introduced. A new micro-machining technology for MEMS components USM & ECM combined micro-machining method is advanced. By the study, the great blast wave and negative pressure effect of ultrasonic frequency vibrating can remove the anode electrolytic passivation membranes produced in micro electrical current density. Micro-ECM can do continuously, so USM & ECM combined micro machining can be realized. Micro-cathode manufacturing technology is studied too. A few kind micro-cathodes with different sections are made by combined electro-discharge micro machining. The USM & ECM combined micro-machining system is built, which machining parameters can be adjusted in a wide ranges. A series of micro-machining basic tests are carried out. The possibility and the technology advantages about USM & ECM combined micro machining have been proved. The study is helpful for improving micro-machining technology and manufacturing MEMS components.
Electrochemical Machining
Ultrasonic machining
Passivation
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Noncircular holes on the surface of turbine rotor blades are usually machined by electrodischarge machining. A recast layer containing numerous micropores and microcracks is easily generated during the electrodischarge machining process due to the rapid heating and cooling effects, which restrict the wide applications of noncircular holes in aerospace and aircraft industries. Owing to the outstanding advantages of pulse electrochemical machining, electrodischarge machining–pulse electrochemical machining combined technique is provided to improve the overall quality of electrodischarge machining-drilled holes. The influence of pulse electrochemical machining processing parameters on the surface roughness and the influence of the electrodischarge machining–pulse electrochemical machining method on the surface quality and accuracy of holes have been studied experimentally. The results indicate that the pulse electrochemical machining processing time for complete removal of the recast layer decreases with the increase in the pulse electrochemical machining current. The low pulse electrochemical machining current results in uneven dissolution of the recast layer, while the higher pulse electrochemical machining current induces relatively homogeneous dissolution. The surface roughness is reduced from 4.277 to 0.299 µm, and the hole taper induced by top-down electrodischarge machining process was reduced from 1.04° to 0.17° after pulse electrochemical machining. On account of the advantages of electrodischarge machining and the pulse electrochemical machining, the electrodischarge machining–pulse electrochemical machining combined technique could be applied for machining noncircular holes with high shape accuracy and surface quality.
Electrochemical Machining
Surface Integrity
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Electrochemical Machining
Titanium alloy
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Electrochemical micro-machining (EMM) has become one of the main machining methods for production of miniaturized parts and components. Utilizing a developed EMM set-up, sets of experiments have been carried out to investigate the influences of some of the predominant electrochemical process parameters such as pulse frequency, feed rate of tool, machining voltage and electrolyte concentration on the machining accuracy of micro-hloes. According to the present investigation, the most effective zone of pulse on time and electrolyte concentration can be considered as 15–50μs and 30–50g/l, respectively, which can gives a desirable machining accuracy for micro-holes. A machining voltage range of 6–10V can be commended to obtain high machining accuracy. From the micrographs of the machined micro-holes, it may be observed that a lower value of electrolyte concentration with moderate machining voltage and moderate value of pulse on time will produce more accurate shape of micro-holes.
Electrochemical Machining
Peak current
Pulse duration
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Micro hole is ode of basic elements for micro device or micro parts. Micro electrochemical machining (ECM) can be applied to the machining of micro holes less than 50 in diameter, which it is not easy to apply other techniques to. For the machining of passivating metals such as stainless steel, machining conditions should be chosen carefully to prevent a passive layer. The machining conditions also affect the machining resolution, In this paper, machining characteristics of micro ECM were investigated according to machining conditions such as electrolyte concentration and pulse conditions. From the investigation, optimal machining conditions were suggested for micro ECM of stainless steel.
Electrochemical Machining
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Electrochemical machining (ECM) has an advantage of no tool wear. On the other side, it is difficult to carry out micro machining in ECM, because the electrode gap in ECM is large. In this paper, electrochemical micro machining with the developed electrode gap control system is demonstrated. The narrow gaps make the control of the process much more complex than normal ECM. Preliminary ECM experiments are carried out in order to investigate a proper condition of machining process. Small hole is machined by using a 0.2mm Ni rod. Drilling time and electrode gap is measured. An optimum machining condition of ECM is determined in terms of machining voltage, machining pulse length, amplitude of electrode for flushing out a contamination, and electrolyte concentration. After preliminary ECM experiments, three-dimensional micro machining is carried out under the optimum condition. First, prismatic electrode whose base is 200μm square is machined by ECM. Next, three-dimensional micro machining is carried out by scanning the prismatic electrode. Three-dimensional shape that is sub-millimeter order is successfully machined.
Electrochemical Machining
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Electrochemical Machining
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Electrochemical machining is a relatively new technique, only being introduced as a commercial technique within the last 70 years. A lot of research was conducted in the 1960s and 1970s, but research on electrical discharge machining around the same time slowed electrochemical machining research. The main influence for the development of electrochemical machining came from the aerospace industry where very hard alloys were required to be machined without leaving a defective layer in order to produce a component which would behave reliably. Electrochemical machining was primarily used for the production of gas turbine blades or to machine materials into complex shapes that would be difficult to machine using conventional machining methods. Tool wear is high and the metal removal rate is slow when machining hard materials with conventional machining methods such as milling. This increases the cost of the machining process overall and this method creates a defective layer on the machined surface. Whereas with electrochemical machining there is virtually no tool wear even when machining hard materials and it does not leave a defective layer on the machined surface. This article reviews the application of electrochemical machining with regards to micro manufacturing and the present state of the art micro electrochemical machining considering different machined materials, electrolytes and conditions used.
Electrochemical Machining
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Micro hole is one of basic elements for micro device or micro parts. Micro electrochemical machining (ECM) can be applied to the machining of micro holes less than 50 ㎛ in diameter, which it is not easy to apply other techniques to. For the machining of passivating metals such as stainless steel, machining conditions should be chosen carefully to prevent a passive layer. The machining conditions also affect the machining resolution. In this paper, machining characteristics of micro ECM were investigated according to machining conditions such as electrolyte concentration and pulse conditions. From the investigation, optimal machining conditions were suggested for micro ECM of stainless steel.
Electrochemical Machining
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Electrochemical machining (ECM) has the advantage that it can quickly produce mirrorlike surfaces without causing any additional damage and stress on the workpiece surface. However, it has a limit in machining accuracy in the machining of microshapes. In this study, short current pulses of microsecond order are introduced to achieve selective dissolution and their effectiveness on the precision of machining is experimentally investigated. The differences among various electrode materials are also tested in terms of durability and machining accuracy, changing machining gap and pulse duration. As a result, it was found that titanium is a suitable material for the electrode for micro-ECM. The condition of 20 μs pulses and a 5 μm machining gap could achieve the machining of 5-μm- deep micropatterns of 50/50 μm line/space into stainless steel.
Electrochemical Machining
Microsecond
Pulse duration
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