The Experts below are selected from a list of 315 Experts worldwide ranked by ideXlab platform

Murali M Sundaram - One of the best experts on this subject based on the ideXlab platform.

  • modeling and fabrication of micro tools by pulsed Electrochemical Machining
    Journal of Materials Processing Technology, 2012
    Co-Authors: Ronnie Mathew, Murali M Sundaram
    Abstract:

    Abstract Accurate and precise micro tools are essential for the microMachining of complex micro features in a wide range of engineering materials including metals and ceramics. Existing micro tool fabrication processes suffer from drawbacks such as surface cracks, residual stress and deformations. Electrochemical Machining of micro tools is proposed in this work to overcome these limitations. In this research, a mathematical model has been developed to predict the diameter of the micro tool fabricated. Experimental verification of the model using an in-house built micro Electrochemical Machining system reveals good correlation with theoretical predictions. Using the procedure described in this paper, very high aspect ratio (280–450) tungsten micro tools have been produced.

  • Modeling and fabrication of micro tools by pulsed Electrochemical Machining
    Journal of Materials Processing Technology, 2012
    Co-Authors: Ronnie Mathew, Murali M Sundaram
    Abstract:

    Accurate and precise micro tools are essential for the microMachining of complex micro features in a wide range of engineering materials including metals and ceramics. Existing micro tool fabrication processes suffer from drawbacks such as surface cracks, residual stress and deformations. Electrochemical Machining of micro tools is proposed in this work to overcome these limitations. In this research, a mathematical model has been developed to predict the diameter of the micro tool fabricated. Experimental verification of the model using an in-house built micro Electrochemical Machining system reveals good correlation with theoretical predictions. Using the procedure described in this paper, very high aspect ratio (280-450) tungsten micro tools have been produced. © 2012 Elsevier B.V. All rights reserved.

Ronnie Mathew - One of the best experts on this subject based on the ideXlab platform.

  • modeling and fabrication of micro tools by pulsed Electrochemical Machining
    Journal of Materials Processing Technology, 2012
    Co-Authors: Ronnie Mathew, Murali M Sundaram
    Abstract:

    Abstract Accurate and precise micro tools are essential for the microMachining of complex micro features in a wide range of engineering materials including metals and ceramics. Existing micro tool fabrication processes suffer from drawbacks such as surface cracks, residual stress and deformations. Electrochemical Machining of micro tools is proposed in this work to overcome these limitations. In this research, a mathematical model has been developed to predict the diameter of the micro tool fabricated. Experimental verification of the model using an in-house built micro Electrochemical Machining system reveals good correlation with theoretical predictions. Using the procedure described in this paper, very high aspect ratio (280–450) tungsten micro tools have been produced.

  • Modeling and fabrication of micro tools by pulsed Electrochemical Machining
    Journal of Materials Processing Technology, 2012
    Co-Authors: Ronnie Mathew, Murali M Sundaram
    Abstract:

    Accurate and precise micro tools are essential for the microMachining of complex micro features in a wide range of engineering materials including metals and ceramics. Existing micro tool fabrication processes suffer from drawbacks such as surface cracks, residual stress and deformations. Electrochemical Machining of micro tools is proposed in this work to overcome these limitations. In this research, a mathematical model has been developed to predict the diameter of the micro tool fabricated. Experimental verification of the model using an in-house built micro Electrochemical Machining system reveals good correlation with theoretical predictions. Using the procedure described in this paper, very high aspect ratio (280-450) tungsten micro tools have been produced. © 2012 Elsevier B.V. All rights reserved.

Yongbin Zeng - One of the best experts on this subject based on the ideXlab platform.

  • The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining.
    Micromachines, 2019
    Co-Authors: Xinmin Zhang, Xudong Song, Pingmei Ming, Xinchao Li, Yongbin Zeng
    Abstract:

    Jet Electrochemical Machining (Jet-ECM) is a significant prospective Electrochemical Machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet Machining, and the effect of jet orientations on Machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of Machining localization and a reduction of MMR for horizontal jet Electrochemical Machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve Machining accuracy.

  • Distribution Manner of Compaction Circular Cylinders in Through-Active-Mask Electrochemical Machining
    Advances in Mechanical Engineering, 2014
    Co-Authors: Hansong Li, Guoqian Wang, Xin Zheng, Yongbin Zeng
    Abstract:

    Electrochemical Machining is widely used in the processing of difficult-to-machine metal materials. And through-mask Electrochemical Machining is a very important technology in the processing array structure of difficult-to-cut metal materials. Traditional through-mask Electrochemical Machining always uses a photoresist as the mask. The production process of a mask is complicated, and the mask cannot be reused. In this paper, through-active-mask Electrochemical Machining to process array structure in difficult-to-machine metal materials was investigated. Compared with traditional Electrochemical Machining masks, a copper-clad laminate is used to make the mask by mechanical Machining in through-active-mask Electrochemical Machining. Also, the mask does not stick together with the workpiece but covers the workpiece by mechanical compaction, so the mask can be reused. In order to ensure the mask is in close contact with the workpiece, we need to arrange many compaction circular cylinders within the flow chan...

  • wire Electrochemical Machining using reciprocated traveling wire
    The International Journal of Advanced Manufacturing Technology, 2014
    Co-Authors: N.s. Qu, H J Ji, Yongbin Zeng
    Abstract:

    Wire Electrochemical Machining (WECM) is a cutting process in which the workpiece acts as an anode and the wire as a cathode. WECM is typically used to cut plates and exhibits a great advantage over wire electro-discharge Machining, namely, the absence of a heat-affected zone around the cutting area. The enhancement of WECM accuracy is a research topic of great interest. In WECM, the homogeneity of the machined slit has a decisive influence on the Machining accuracy. This is the first study in which the integration of pulse Electrochemical Machining (ECM) and a reciprocated traveling wire electrode was used to improve the homogeneity of this slit. The experimental results show that the combination of pulse ECM and a reciprocated traveling wire electrode could enhance the accuracy of WECM and that generally a low applied voltage, pulse duty cycle, and electrolyte concentration; an appropriate traveling wire velocity; and a high pulse frequency and feeding rate enhance the accuracy and stability of WECM. Finally, a microstructure with a slit width of 177 μm, with a standard deviation of 1.5 μm, and with an aspect ratio of 113 was fabricated on a stainless steel substrate measuring 20 mm in thickness.

  • wire Electrochemical Machining with axial electrolyte flushing for titanium alloy
    Chinese Journal of Aeronautics, 2013
    Co-Authors: N.s. Qu, Xiaolong Fang, Wei Li, Yongbin Zeng
    Abstract:

    Abstract Titanium and its alloys have found very wide application in aerospace due to their excellent characteristics although their processing is still a challenge. Electrochemical Machining is an important issue in the fabrication of titanium and titanium alloys. Wire Electrochemical Machining (WECM) is mainly used for workpiece cutting under the condition of different thickness plates. It has a great advantage over wire electro-discharge Machining, which is the absence of heat-affected zone around the cutting area. Moreover, the wire electrode in WECM could be used repetitively because it is not worn out. Thus, much attention has been paid to WECM. The effective way of removing electrolysis products is of importance to WECM. In this paper, the axial electrolyte flushing is presented to WECM for removing electrolysis products and renewing electrolyte. The Taguchi experiment is conducted to optimize the Machining parameters, such as wire feedrate, Machining voltage, electrolyte concentration, etc. Experimental results show that WECM with axial electrolyte flushing is a promising issue in the fabrication of titanium alloy (TC1). The feasibility of multi-wire Electrochemical Machining is also demonstrated to improve the Machining productivity of WECM.

  • enhancement of mass transport in micro wire Electrochemical Machining
    Cirp Annals-manufacturing Technology, 2012
    Co-Authors: Yongbin Zeng, Qia Yu, Shaohua Wang
    Abstract:

    In micro wire Electrochemical Machining, the Machining gap between the cathode wire and anode workpiece is so tiny that it is difficult to remove electrolysis products and renew electrolyte, leading to frequent electric short circuits and quite low processing speed. Three approaches of enhancing mass transport, electrolyte flushing along the wire, wire traveling in one direction and micro-vibration of cathode wire have been studied theoretically and experimentally in this paper. The results demonstrate that the proposed methods significantly enhance the mass transport and thus improve the Machining stability, the productivity and the surface quality for micro wire Electrochemical Machining.

Andreas Schubert - One of the best experts on this subject based on the ideXlab platform.

  • Design of Electrochemical Machining Processes by Multiphysics Simulation
    2020
    Co-Authors: Stephan F. Jahn, Andreas Schubert
    Abstract:

    The basic principle of all applica- tions of Electrochemical Machining (ECM) is the anodic dissolution of a metallic workpiece at the interface to a liquid ionic conductor, the electrolyte, under the inuence of electric

  • Surface Characterization of Particle Reinforced Aluminum-matrix Composites Finished by Pulsed Electrochemical Machining☆
    Procedia CIRP, 2016
    Co-Authors: Matthias Hackert-oschätzchen, Norbert Lehnert, André Martin, Gunnar Meichsner, Andreas Schubert
    Abstract:

    Aluminum matrix composites (AMCs) are difficult to machine conventionally. Pulsed Electrochemical Machining (PECM) is an alternative method to machine AMCs. Metals can be machined without contact, independent of material hardness and without mechanical or thermal impact. During the process no tool wear occurs. The AMCs consist of an aluminum matrix, which is easily to machine with PECM, and SiC-particles, which cannot be dissolved during the Electrochemical Machining process applying neutral electrolytes. This combination leads to a special behavior of dissolution and anodization. In this study, the influence on the surface layer, caused by Pulsed Electrochemical Machining of AMCs, is analyzed.

  • Fast Determination of the Material Removal Characteristics in Pulsed Electrochemical Machining
    Procedia CIRP, 2016
    Co-Authors: Gunnar Meichsner, Matthias Hackert-oschätzchen, Andreas Schubert, M. Krönert, Jan Edelmann, Matthias Putz
    Abstract:

    Abstract Electrochemical Machining (ECM) of metallic materials is a complex manufacturing process. Currently the design of the process parameters and the cathode geometry is determined by expensive and inefficient experiments. This paper introduces a method for a fast determination of the material removal characteristics in pulsed Electrochemical Machining (PECM). The determination is performed by help of removal experiments using a PEMCenter 8000. As example the material removal characteristics of stainless steel 1.4301 under PECM conditions are shown. Based on the resulting mathematical description of the material removal characteristics a design of PECM processes by analytical calculations or multiphysics simulation is feasible.

  • Evaluation of the Technical-Economic Potential of Particle- Reinforced Aluminum Matrix Composites and Electrochemical Machining
    IOP Conference Series: Materials Science and Engineering, 2016
    Co-Authors: Andreas Schubert, Matthias Hackert-oschätzchen, Norbert Lehnert, Gunnar Meichsner, Uwe Götze, Franziska Herold, A. Schmidt
    Abstract:

    Compared to conventional cutting, the processing of materials by Electrochemical Machining offers some technical advantages like high surface quality, no thermal or mechanical impact on the work piece and preservation of the microstructure of the work piece material. From the economic point of view, the possibility of process parallelization and the absence of any process-related tool wear are mentionable advantages of Electrochemical Machining. In this study, based on experimental results, it will be evaluated to what extent the Electrochemical Machining is technically and economically suitable for the finish-Machining of particle- reinforced aluminum matrix composites (AMCs). Initial studies showed that Electrochemical Machining - in contrast to other Machining processes - has the potential to fulfil demanding requirements regarding precision and surface quality of products or components especially when applied to AMCs. In addition, the investigations show that processing of AMCs by Electrochemical Machining requires less energy than the Electrochemical Machining of stainless steel. Therefore, an evaluation of Electrochemically machined AMCs - compared to stainless steel - from a technical and an economic perspective will be presented in this paper. The results show the potential of electro-chemically machined AMCs and contribute to the enhancement of instruments for technical-economic evaluations as well as a comprehensive innovation control.

  • microstructuring of carbide metals applying jet Electrochemical Machining
    Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology, 2013
    Co-Authors: Matthias Hackertoschatzchen, André Martin, Gunnar Meichsner, Andreas Schubert, Mike Zinecker
    Abstract:

    Abstract Electrochemical Machining (ECM) is a potential procedure for high precision micromanufacturing. Especially the Machining of work pieces without any thermal or mechanical impact is a significant feature. Additionally, the Electrochemical dissolution behavior of the work piece material is only defined by its Electrochemical attributes. Hence, mechanical characteristics such as the material's hardness and the ductility have no influence. This makes ECM an alternative process for mechanically hard to machine materials. In this study, a special procedure for Machining microgeometries in carbide metal alloys is investigated, whereat a continuous electrolytic free jet (Jet Electrochemical Machining – Jet-ECM) is applied. The special characteristic of this technology is the restriction of the electric current to a confined area by the jet, which leads to a high localization of the removals. Even complex structures can be machined by the help of continuous direct current. Hence, higher dissolution rates compared to pulsed Electrochemical processes can be achieved. In the experiments the Machining of step holes and grooves in tungsten carbide alloys is performed. Therefore, point erosions without nozzle movement and linear erosions by single- and multi-axis motions of the tool are conducted. In addition, three-dimensional shaping of the investigated materials is presented by overlapping linear erosions.

Shaohua Wang - One of the best experts on this subject based on the ideXlab platform.

  • enhancement of mass transport in micro wire Electrochemical Machining
    Cirp Annals-manufacturing Technology, 2012
    Co-Authors: Yongbin Zeng, Qia Yu, Shaohua Wang
    Abstract:

    In micro wire Electrochemical Machining, the Machining gap between the cathode wire and anode workpiece is so tiny that it is difficult to remove electrolysis products and renew electrolyte, leading to frequent electric short circuits and quite low processing speed. Three approaches of enhancing mass transport, electrolyte flushing along the wire, wire traveling in one direction and micro-vibration of cathode wire have been studied theoretically and experimentally in this paper. The results demonstrate that the proposed methods significantly enhance the mass transport and thus improve the Machining stability, the productivity and the surface quality for micro wire Electrochemical Machining.