Article
Chemistry, Analytical
Weijing Kong, Ziyu Liu, Rudong Zhang, Yongbin Zeng
Summary: With the development of MEMS, there is an increasing demand for machining difficult-to-machine metal micro parts. Microelectric discharge machining is effective but causes recast layers. In this study, we propose wire electrochemical discharge micro-machining (WECDMM) with a new electrolyte system to remove recast layers. We optimize the electrolyte and analyze the effects of process parameters on machining quality.
Article
Automation & Control Systems
Lukas Steinhoff, Rico Ottermann, Folke Dencker, Marc Christopher Wurz
Summary: Precision machining is becoming more important as the demand for higher surface quality increases. A study demonstrated a process strategy for finishing copper surfaces using batch-manufactured micro-grinding tools in an electrochemically assisted grinding process. By using finer abrasives grains and an optimized grinding process, similar or better surface roughness values could be achieved. The combination of the shown grinding process and anodic oxidation seems promising for achieving high surface finishes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Chemistry, Analytical
Douyan Zhao, Zhaoyang Zhang, Hao Zhu, Zenghui Cao, Kun Xu
Summary: The study proposed a laser-assisted ECDM method for glass micro-grooving, combining ECDM and laser machining. This method can solve the problems of uneven bottom surface, non-straight edges, and V-shaped cross-section in the micro-grooving process of glass.
Article
Materials Science, Ceramics
Chongjun Wu, Tangyong Zhang, Weicheng Guo, Xiankai Meng, Zishan Ding, Steven Y. Liang
Summary: This paper investigates the efficient grinding mechanism of ceramics using Laser Assisted Grinding (LAG) method. Three different types of grooves were designed and tested, and it was found that the annular groove had better surface integrity under a lower grinding force. It is suggested that preparing curved surface grooves with a lower distance gap can directly improve grinding efficiency and surface integrity.
CERAMICS INTERNATIONAL
(2022)
Article
Automation & Control Systems
Yi Xu, Baoyang Jiang
Summary: Electrochemical discharge machining (ECDM) is a technology used for micromachining of non-conductive materials, but deep micro hole drilling encounters problems due to bubble accumulation at the entrance hole; recent research shows that improving electrolyte circulation through the magnetohydrodynamic effect can enhance machining efficiency.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Junqi Wei, Yong Zhang, Guojun Dong, Liangchi Zhang, Feihu Zhang
Summary: This paper investigates the potential application of electrical discharge grinding in Inconel 718 machining. Various methods are used to characterize the surface integrity of Inconel 718 in electrical discharge grinding, including observing the surface morphology, detecting subsurface grain deformation, studying corrosion resistance, and exploring nano-mechanical properties.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Ali Mehrvar, Alireza Mirak
Summary: CMSX-4 nickel base superalloy is a second-generation single crystal alloy with improved mechanical properties. Achieving minimal surface defects and roughness is crucial for the manufacturing process of this superalloy. A comparison of the surface condition after grinding, wire electro discharge machining (WEDM), and electrochemical machining (ECM) was conducted, revealing that ECM and grinding produced the most desirable surface roughness. Additionally, ECM showed no observed defects in the SEM images. The hardness values also indicated the effectiveness of ECM. Therefore, ECM is a suitable alternative for manufacturing parts with smooth surfaces and minimal defects.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Engineering, Multidisciplinary
Niladri Mandal, Nitesh Kumar, Alok Kumar Das
Summary: This study demonstrates the feasibility of the powder-mixed micro-electrochemical discharge machining (PMECDM) process in fabricating micro-holes on C103 niobium-based alloy for high temperature applications. Compared to the classical micro-electrochemical discharge machining (MECDM), PMECDM showed a faster material removal rate and better surface finish.
DEFENCE TECHNOLOGY
(2023)
Article
Engineering, Industrial
Chengwei Kang, Fusheng Liang, Gang Shen, Dongxu Wu, Fengzhou Fang
Summary: This study investigates the fabrication of micro-dimples using microabrasive jet machining, finding that changing processing time and air pressure is the most efficient way to vary dimple dimension. Nozzle stand-off distance and air pressure play a crucial role in determining dimple geometry. By optimizing parameter combinations, a variety of desired morphologies can be obtained.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Chemistry, Analytical
Weidong Tang, Yuhao Zhu, Xiaoming Kang, Cong Mao
Summary: Electrochemical discharge machining (ECDM) is a promising non-traditional technology for machining non-conductive materials. The discharge plays a crucial role in material removal, and the discharge current reflects the discharge state. However, the discharge characteristics in ECDM still need further investigation. High-speed imaging technology was used to study the discharge characteristics, which were classified into three types based on the comparison of discharge images with discharge current. The discharge was found to exert force on the gas film and change its shape, and the discharge frequency increased with the applied voltage.
Article
Materials Science, Coatings & Films
Nihal Ekmekci, Yasin Efe
Summary: This study investigates the deposition of hydroxyapatite on the modified surface of titanium alloy using hydroxyapatite powder mixed electrical discharge machining (HA-PMEDM). The effects of different process parameters on surface roughness, surface topography, and powder deposition were evaluated. The results show that the highest rate of hydroxyapatite deposition to the machined surface was observed when using a pulse current of 22 A and a pulse-on duration of 100 μs in micro additive dielectric liquid.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Chemistry, Physical
Jing Li, Wanwan Chen, Yongwei Zhu
Summary: This study proposes a new mechanism for two-dimensional ultrasonic assisted grinding-electrolysis-discharge generating machining (2UG-E-DM). The influence of vibration directions on grinding characteristics and surface morphology was analyzed through motion simulation. Comparative experiments confirmed the effect of ultrasonic assistance on weakening of grinding force, widening of surface pits, and leveling of surface morphology. Simulation analysis of a single abrasive particle verified the experimental results. Machining tests showed that increasing workpiece and tool amplitude resulted in a faster reduction of normal force grinding force compared to tangential force grinding force. The effect of surface electrolysis discharge machining was significant, increasing the number of exposed particles while reducing both the residual height and surface roughness through vibration grinding. Increasing the two-dimensional amplitude to 5 μm expanded the grinding domain and significantly reduced surface roughness through the dragging and rolling of reinforced particles, resulting in good surface quality.
Article
Chemistry, Multidisciplinary
Yung Na, Ui Seok Lee, Bo Hyun Kim
Summary: In this study, micro-grinding was conducted to investigate the machining performance of alumina and zirconia. The use of polycrystalline diamond (PCD) as the tool material and micro-electrical discharge machining (EDM) for fabricating PCD micro-tools were effective in machining hard and brittle ceramics. Controlling the working capacitance in micro-EDM allowed for achieving different edge radii and tool surface roughness, resulting in reduced cutting force and improved surface finish.
APPLIED SCIENCES-BASEL
(2021)
Review
Materials Science, Multidisciplinary
Sergey N. Grigoriev, Khaled Hamdy, Marina A. Volosova, Anna A. Okunkova, Sergey V. Fedorov
Summary: Ceramics are widely used in engineering applications due to their unique properties, but their high hardness and brittleness make traditional machining difficult. Electrical discharge machining is considered a method for machining non-conductive ceramics. However, current results of ceramic machining using electrical discharge still fall short of expectations.
MATERIALS & DESIGN
(2021)
Article
Multidisciplinary Sciences
Mahaveer Prasad Sharma, Pankaj Kumar Gupta, Gaurav Kumar
Summary: Electrochemical discharge machining (ECDM) is a promising method for the machining of micro- and nano-sized product components. However, controlling the process parameters for optimal performance remains a challenge. A finite element study was conducted to explore the physics of the process and analyze the differences between experimental and simulation results.
ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING
(2023)