The Experts below are selected from a list of 858 Experts worldwide ranked by ideXlab platform
Yongbin Zeng - One of the best experts on this subject based on the ideXlab platform.
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Improving Machining efficiency in wire electrochemical microMachining of array microstructures using axial vibration-assisted multi-wire electrodes
Journal of Manufacturing Processes, 2017Co-Authors: Haidong He, Yongbin Zeng, Ningsong QuAbstract:Abstract Wire electrochemical microMachining (WECMM) is a promising approach for fabrication of high-quality microcomponents. However, its industrial applications remain limited owing to its relatively low Machining efficiency, which is significantly affected by the efficiency with which electrolyte can be refreshed in the narrow Machining Gap. In this paper, a method of WECMM using axial vibration-assisted multi-wire electrodes with high traveling speed is proposed to improve upon the Machining efficiency of WECMM. A flow-field model was established to simulate the flow field in the Machining Gap when the tool was traveling. A series of experiments are performed to optimize the Machining parameters. Experimental results reveal that microstructures with negligible taper, high aspect ratio and good consistency can be effectively fabricated using this method. Finally, WECMM using 15-wire electrodes at a maximum feed rate of 5.0 μm/s is realized, at a total Machining rate of 75.0 μm/s being achieved. With the optimal Machining parameters, a multiple-slit microstructure with high aspect ratio of 20 is fabricated using 15-wire electrodes, and X-shape microparts of high surface quality ( R a = 128.0 nm, R q = 162.0 nm and R max = 1.72 μm) are mass produced using 7-wire electrodes.
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Wire electrochemical microMachining of metallic glass using a carbon nanotube fiber electrode
Journal of Alloys and Compounds, 2017Co-Authors: Lingchao Meng, Xiaolong Fang, Yongbin Zeng, Di ZhuAbstract:Metallic glasses are promising materials for realizing high-performance micro devices in micro-electromechanical systems (MEMS) owing to their excellent functional and structural characteristics. A significant limitation to their application is the challenge of shaping them on a microscale. A technique of wire electrochemical microMachining (WECMM) with a carbon nanotube fiber (CNF) as tool electrode is proposed for microstructure fabrication of metallic glass. WECMM is a type of electrochemical microMachining (ECMM) that is increasingly recognized as a flexible and effective technology to fabricate complex-shaped micro components. Taking the example of a Ni-based metallic glass, Ni72Cr19Si7B2, the polarization and fabrication characteristics in dilute acid electrolytes are investigated. As the Machining Gap is very small in WECMM, efficient mass transport is extremely important to improve the Machining efficiency, stability, and quality. The efficiency of enhancing mass transport using a CNF electrode in this work is shown by flow-field simulation and hydrophilicity analysis, as well as experimental investigation. The maximum feed rate can be doubled and the homogeneity of machined slits improved more than five times compared with the results obtained using a smooth tungsten wire. Finally, complex microstructures based on metallic glass are fabricated by WECMM using a CNF electrode successfully.
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effect of wire cathode surface hydrophilia when using a travelling wire in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2016Co-Authors: Kun Xu, Yongbin Zeng, Peng Li, Xiaolong FangAbstract:Abstract Wire electrochemical micro Machining (WEMM) is receiving considerable attention in the production of metal micro structures because it produces smooth, burr-free surfaces without heat damaged layer and the tool is not worn out. As the Machining Gap is so small in WEMM, the process of mass transport is important, and its consideration becomes necessary when attempting to improve productivity and processing quality. The travelling wire method has been used in previous studies to enhance mass transport in WEMM. However, the ability of the travelling wire was underutilized because wire cathodes with smooth surfaces were used. Tungsten wires with rough surfaces have better hydrophilia than those with smooth surfaces, which is good for enhancing mass transport. In this paper, tungsten wire with a rough surface is prepared using chemical etching, and is adopted as the cathode in cobalt base alloy Machining. The influence of the smoothness and hydrophilia of the wire cathode surface on WEMM is discussed theoretically, and the effects on process stability and processing quality are studied experimentally.
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study of surface roughness in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2015Co-Authors: Kun Xu, Yongbin Zeng, Peng LiAbstract:Abstract Wire electrochemical micro Machining (WEMM) has many advantages in Machining metal structures. Even though surface roughness is one of the important indicators for measuring processing quality, it has not been paid enough attention to when using WEMM. In this paper, cathode travelling and anode vibration were used to enhance mass transport and to improve the Machining surface roughness, because electrolytic products accumulate easily in the Machining Gap, which causes a rough surface. Moreover, changes in the surface roughness under cathode travelling, anode vibration and pulse conditions were experimentally investigated, and surfaces with R a = 0.058 μm and R max = 0.670 μm were obtained. Micro cams with smooth faces were fabricated using optimal Machining conditions.
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wire electrochemical Machining with monodirectional traveling wire
The International Journal of Advanced Manufacturing Technology, 2015Co-Authors: Yongbin Zeng, Qia Yu, Xiaolong Fang, Kun Xu, Hansong Li, N S QuAbstract:Wire electrochemical Machining (WECM) is a promising approach for the fabrication of various metal parts. In WECM, the Machining stability and accuracy are significantly affected by the mass transport rate in the Machining Gap. In this paper, a monodirectional traveling wire is introduced in the WECM process to remove the electrolysis products and renew the electrolyte in the Machining Gap. A flow field model of the electrolyte in the Machining Gap is built. A Machining system with a monodirectional traveling wire unit has been developed. Both the flow field model and the experimental results illustrate that the monodirectional traveling wire is a notably effective approach for renewing the electrolyte and removing the electrolysis products in a narrow Machining Gap during the WECM process. Parameters such as the wire traveling velocity, the feeding rate, and the applied voltage are optimized. Finally, structures with uniform slit width on stainless steel 304 with a thickness of 5 mm have been fabricated.
Peng Li - One of the best experts on this subject based on the ideXlab platform.
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effect of wire cathode surface hydrophilia when using a travelling wire in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2016Co-Authors: Kun Xu, Yongbin Zeng, Peng Li, Xiaolong FangAbstract:Abstract Wire electrochemical micro Machining (WEMM) is receiving considerable attention in the production of metal micro structures because it produces smooth, burr-free surfaces without heat damaged layer and the tool is not worn out. As the Machining Gap is so small in WEMM, the process of mass transport is important, and its consideration becomes necessary when attempting to improve productivity and processing quality. The travelling wire method has been used in previous studies to enhance mass transport in WEMM. However, the ability of the travelling wire was underutilized because wire cathodes with smooth surfaces were used. Tungsten wires with rough surfaces have better hydrophilia than those with smooth surfaces, which is good for enhancing mass transport. In this paper, tungsten wire with a rough surface is prepared using chemical etching, and is adopted as the cathode in cobalt base alloy Machining. The influence of the smoothness and hydrophilia of the wire cathode surface on WEMM is discussed theoretically, and the effects on process stability and processing quality are studied experimentally.
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study of surface roughness in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2015Co-Authors: Kun Xu, Yongbin Zeng, Peng LiAbstract:Abstract Wire electrochemical micro Machining (WEMM) has many advantages in Machining metal structures. Even though surface roughness is one of the important indicators for measuring processing quality, it has not been paid enough attention to when using WEMM. In this paper, cathode travelling and anode vibration were used to enhance mass transport and to improve the Machining surface roughness, because electrolytic products accumulate easily in the Machining Gap, which causes a rough surface. Moreover, changes in the surface roughness under cathode travelling, anode vibration and pulse conditions were experimentally investigated, and surfaces with R a = 0.058 μm and R max = 0.670 μm were obtained. Micro cams with smooth faces were fabricated using optimal Machining conditions.
Kun Xu - One of the best experts on this subject based on the ideXlab platform.
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effect of wire cathode surface hydrophilia when using a travelling wire in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2016Co-Authors: Kun Xu, Yongbin Zeng, Peng Li, Xiaolong FangAbstract:Abstract Wire electrochemical micro Machining (WEMM) is receiving considerable attention in the production of metal micro structures because it produces smooth, burr-free surfaces without heat damaged layer and the tool is not worn out. As the Machining Gap is so small in WEMM, the process of mass transport is important, and its consideration becomes necessary when attempting to improve productivity and processing quality. The travelling wire method has been used in previous studies to enhance mass transport in WEMM. However, the ability of the travelling wire was underutilized because wire cathodes with smooth surfaces were used. Tungsten wires with rough surfaces have better hydrophilia than those with smooth surfaces, which is good for enhancing mass transport. In this paper, tungsten wire with a rough surface is prepared using chemical etching, and is adopted as the cathode in cobalt base alloy Machining. The influence of the smoothness and hydrophilia of the wire cathode surface on WEMM is discussed theoretically, and the effects on process stability and processing quality are studied experimentally.
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study of surface roughness in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2015Co-Authors: Kun Xu, Yongbin Zeng, Peng LiAbstract:Abstract Wire electrochemical micro Machining (WEMM) has many advantages in Machining metal structures. Even though surface roughness is one of the important indicators for measuring processing quality, it has not been paid enough attention to when using WEMM. In this paper, cathode travelling and anode vibration were used to enhance mass transport and to improve the Machining surface roughness, because electrolytic products accumulate easily in the Machining Gap, which causes a rough surface. Moreover, changes in the surface roughness under cathode travelling, anode vibration and pulse conditions were experimentally investigated, and surfaces with R a = 0.058 μm and R max = 0.670 μm were obtained. Micro cams with smooth faces were fabricated using optimal Machining conditions.
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wire electrochemical Machining with monodirectional traveling wire
The International Journal of Advanced Manufacturing Technology, 2015Co-Authors: Yongbin Zeng, Qia Yu, Xiaolong Fang, Kun Xu, Hansong Li, N S QuAbstract:Wire electrochemical Machining (WECM) is a promising approach for the fabrication of various metal parts. In WECM, the Machining stability and accuracy are significantly affected by the mass transport rate in the Machining Gap. In this paper, a monodirectional traveling wire is introduced in the WECM process to remove the electrolysis products and renew the electrolyte in the Machining Gap. A flow field model of the electrolyte in the Machining Gap is built. A Machining system with a monodirectional traveling wire unit has been developed. Both the flow field model and the experimental results illustrate that the monodirectional traveling wire is a notably effective approach for renewing the electrolyte and removing the electrolysis products in a narrow Machining Gap during the WECM process. Parameters such as the wire traveling velocity, the feeding rate, and the applied voltage are optimized. Finally, structures with uniform slit width on stainless steel 304 with a thickness of 5 mm have been fabricated.
Rolf Wuthrich - One of the best experts on this subject based on the ideXlab platform.
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the Machining Gap during constant velocity feed glass micro drilling by spark assisted chemical engraving
Journal of Manufacturing Processes, 2015Co-Authors: Jana Abou D Ziki, Rolf WuthrichAbstract:Abstract Spark Assisted Chemical Engraving (SACE) is one among several technologies used to micro-drill glass. So far, two strategies are used in SACE: gravity-feed and constant velocity-feed drilling. Contrary to gravity-feed, constant velocity-feed drilling is less studied. The last presents several advantages from the technological point of view, the major one being that Machining can be conducted with no contact between the tool and the glass work-piece if a Gap between both surfaces can be maintained. In this paper a methodology to measure the Gap between the tool and work-piece is presented. The Gap is measured for different Machining conditions that allow varying the local flushing and heating. It is found that both factors affect the Gap which is estimated to be in the order of 5–10 μm for typical SACE Machining conditions. A model that estimates the Machining Gap is proposed based on the process understanding brought throughout this work. Further, it is found that the bottom hole surface texture is affected by the electrolyte flow within the Machining Gap.
Xiaolong Fang - One of the best experts on this subject based on the ideXlab platform.
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Wire electrochemical microMachining of metallic glass using a carbon nanotube fiber electrode
Journal of Alloys and Compounds, 2017Co-Authors: Lingchao Meng, Xiaolong Fang, Yongbin Zeng, Di ZhuAbstract:Metallic glasses are promising materials for realizing high-performance micro devices in micro-electromechanical systems (MEMS) owing to their excellent functional and structural characteristics. A significant limitation to their application is the challenge of shaping them on a microscale. A technique of wire electrochemical microMachining (WECMM) with a carbon nanotube fiber (CNF) as tool electrode is proposed for microstructure fabrication of metallic glass. WECMM is a type of electrochemical microMachining (ECMM) that is increasingly recognized as a flexible and effective technology to fabricate complex-shaped micro components. Taking the example of a Ni-based metallic glass, Ni72Cr19Si7B2, the polarization and fabrication characteristics in dilute acid electrolytes are investigated. As the Machining Gap is very small in WECMM, efficient mass transport is extremely important to improve the Machining efficiency, stability, and quality. The efficiency of enhancing mass transport using a CNF electrode in this work is shown by flow-field simulation and hydrophilicity analysis, as well as experimental investigation. The maximum feed rate can be doubled and the homogeneity of machined slits improved more than five times compared with the results obtained using a smooth tungsten wire. Finally, complex microstructures based on metallic glass are fabricated by WECMM using a CNF electrode successfully.
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effect of wire cathode surface hydrophilia when using a travelling wire in wire electrochemical micro Machining
Journal of Materials Processing Technology, 2016Co-Authors: Kun Xu, Yongbin Zeng, Peng Li, Xiaolong FangAbstract:Abstract Wire electrochemical micro Machining (WEMM) is receiving considerable attention in the production of metal micro structures because it produces smooth, burr-free surfaces without heat damaged layer and the tool is not worn out. As the Machining Gap is so small in WEMM, the process of mass transport is important, and its consideration becomes necessary when attempting to improve productivity and processing quality. The travelling wire method has been used in previous studies to enhance mass transport in WEMM. However, the ability of the travelling wire was underutilized because wire cathodes with smooth surfaces were used. Tungsten wires with rough surfaces have better hydrophilia than those with smooth surfaces, which is good for enhancing mass transport. In this paper, tungsten wire with a rough surface is prepared using chemical etching, and is adopted as the cathode in cobalt base alloy Machining. The influence of the smoothness and hydrophilia of the wire cathode surface on WEMM is discussed theoretically, and the effects on process stability and processing quality are studied experimentally.
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wire electrochemical Machining with monodirectional traveling wire
The International Journal of Advanced Manufacturing Technology, 2015Co-Authors: Yongbin Zeng, Qia Yu, Xiaolong Fang, Kun Xu, Hansong Li, N S QuAbstract:Wire electrochemical Machining (WECM) is a promising approach for the fabrication of various metal parts. In WECM, the Machining stability and accuracy are significantly affected by the mass transport rate in the Machining Gap. In this paper, a monodirectional traveling wire is introduced in the WECM process to remove the electrolysis products and renew the electrolyte in the Machining Gap. A flow field model of the electrolyte in the Machining Gap is built. A Machining system with a monodirectional traveling wire unit has been developed. Both the flow field model and the experimental results illustrate that the monodirectional traveling wire is a notably effective approach for renewing the electrolyte and removing the electrolysis products in a narrow Machining Gap during the WECM process. Parameters such as the wire traveling velocity, the feeding rate, and the applied voltage are optimized. Finally, structures with uniform slit width on stainless steel 304 with a thickness of 5 mm have been fabricated.
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Electrochemical drilling with vacuum extraction of electrolyte
Journal of Materials Processing Technology, 2010Co-Authors: Wei Wang, N S Qu, S.f. Huang, Xiaolong FangAbstract:Forward flow pattern of electrolyte is widely used in electrochemical drilling (ECD) process. But electrolyte in the Machining Gap presents a sharp divergent flow which causes an abnormal dissolution and even harmful sparking. Reverse flow of electrolyte leads to a stable Machining process but is rarely used due to the poor application feasibility. In this paper, an electrochemical drilling method with vacuum extraction of electrolyte has been proposed. Vacuum extraction of electrolyte greatly facilitates the application of reverse flow in electrochemical drilling. Flow distributions along the Machining Gap with different electrolyte flow pattern are compared numerically and experimentally. Reverse flow using vacuum extraction is shown to improve the process stability while diminishing sparking and formation of striations. Machining characteristics of vacuum extraction are investigated experimentally. To minimize the radial overcut of machined hole by electrochemical Machining with vacuum extraction of electrolyte, the orthogonal design is used to optimize process parameters such as initial Machining Gap, applied voltage, tool feed rate, and electrolyte concentration. Good results have been obtained in the experiments with optimized parameters.
