Article
Engineering, Manufacturing
Julfekar Arab, Pradeep Dixit
Summary: This article addresses the issue of gas bubble entrapment in electrochemical discharge machining (ECDM) when using a multi-tip tool array (MTA) for the first time. The evaporation and condensation of the electrolyte vapor on the tool shank interrupts the electrochemical discharge process, leading to poor-quality microholes and glass substrate breakage. Experimental analysis shows that increasing electrode lengths and pitch size can significantly reduce the bubble entrapment frequency and improve the uniformity of electrochemical discharges, essential for obtaining high-quality microholes.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
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
Feng Wang, Jianshe Zhao, Zhiming Qiang, Yafeng He, Min Kang, Zongjun Tian
Summary: This study proposed a pulse-vibration electrochemical machining method to enhance the machining localization of parallel micro-grooves. The effects of different electrochemical machining methods on the accuracy and consistency of micro-grooves were investigated through simulation and experiments. The results verified that combining the pulse-vibration ECM method and the flow-direction switching mode could significantly improve the machining accuracy and consistency of micro-grooves.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Peng Tengfei, Wang Kan, Li Minghao, Liu Yong
Summary: The UA-WECMM technology, by adding ultrasonic vibration, improves the mass transfer problem in WECMM and enhances machining performance effectively.
Experimental results show that with the increase of ultrasonic amplitude, the slit width can be reduced and the surface roughness can be improved, demonstrating the effectiveness of this technology in fabricating metal microstructures.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
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
Engineering, Manufacturing
S. Debnath, M. Masanta, B. Bhattacharyya
Summary: This research focuses on the fabrication and application of wire in wire electrochemical machining (WECM). A unique methodology is employed to fabricate wire with repeated geometries, and the effects on surface quality, homogeneity, and dimensional accuracy are analyzed. The results show that the proposed methods can improve the surface quality, homogeneity, and dimensional accuracy of microfeatures in WECM.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Chemical
Zhe-Yong Shen, Hai-Ping Tsui
Summary: This paper discusses the use of an ultrasonic vibration-integrated array electrode for micro-hole drilling in 301 stainless steel. Experimental results show that with the optimal parameter combination, such drilling can achieve a minimum average diagonal length and a smaller amount of variation in diagonal length, improving the inlet and outlet taper angle of micro-holes.
Article
Engineering, Mechanical
Dengyong Wang, Qianqian Wang, Jun Zhang, Huayong Le, Zengwei Zhu, Di Zhu
Summary: This paper presents a novel counter-rotating electrochemical machining (CRECM) method for fabricating intensive cylindrical pillar arrays on metallic surfaces, achieving desired pillar structures with a specific-designed cathode tool and utilizing a hybrid additive manufacturing process for tool fabrication.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Materials Science, Multidisciplinary
Hanheng Du, Zhiwei Zhu, Zuankai Wang, Suet To
Summary: This study proposes a novel piezoelectrically actuated cutting system for fabricating high-aspect-ratio and hierarchical micro/nanostructure arrays. The mechanical structure is designed based on the circular flexure hinge, and a finite element model is established to analyze its resonant frequencies and mode shapes. The effectiveness and flexibility of the proposed cutting system are demonstrated by fabricating micro/nanostructure arrays with varying features.
MATERIALS & DESIGN
(2023)
Article
Automation & Control Systems
Jia Liu, Yan Liu, Xiaochen Jiang, Di Zhu
Summary: The novel ECM cathode tool with comb-shaped insulator proposed in this paper significantly improves the machining quality and flow field stability of array flow channels. Experimental results demonstrate that using this tool enhances the flatness of the rib tops and surface quality of the channel bottoms during the machining process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
S. Kunar
Summary: This research utilizes maskless microelectrochemical jet machining to produce microtextures on stainless steel surfaces, achieving high-quality micro-patterned samples over large areas through a masked tool movement strategy. High-pressure electrolyte flow through a textured tool is developed to obtain controlled dimensions in the microtextures.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Guo-Dong Liu, Yu-Lan Zhu, Sheng-Gui Liu, Chao-Jiang Li
Summary: Using a conductive-material-filled electrode can enhance sidewall insulation performance, leading to better durability and sidewall insulation in micro electrochemical machining processes.
ADVANCES IN MANUFACTURING
(2023)
Article
Electrochemistry
Zhongqi Zhou, Xiaolong Fang, Yongbin Zeng, Di Zhu
Summary: This paper focuses on the equilibrium machining gap distribution in wire electrochemical micromachining (WECMM) and establishes a two-dimensional electric field model to investigate the evolution process of slit profile. The study found that in the machining equilibrium status, the machining gap exponentially increases with the increase of the induced angle between the wire electrode normal direction and its feeding direction.
JOURNAL OF THE ELECTROCHEMICAL SOCIETY
(2021)
Review
Computer Science, Interdisciplinary Applications
Sergio Tadeu Almeida, John P. T. Mo, Cees Bil, Songlin Ding, Xiangzhi Wang
Summary: The study discusses a synergistic combination of a novel machining technique WEDM with an industrial robot (IR) as the servo, successfully controlled through frequency modulation for machining hard-to-cut conductive materials yet free of vibration.
ARCHIVES OF COMPUTATIONAL METHODS IN ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Sergey N. Grigoriev, Petr M. Pivkin, Mikhail P. Kozochkin, Marina A. Volosova, Anna A. Okunkova, Artur N. Porvatov, Alexander A. Zelensky, Alexey B. Nadykto
Summary: The field of applied wire electrical discharge machining (WEDM) is expanding due to increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co provide distinct advantages over other cutting materials, and the choice of WEDM modes is crucial for ensuring dimensional quality. The study showed the importance of monitoring acoustic emission parameters for controlling WEDM stability and productivity, especially when machining hard alloys with high heat resistance and low heat conductivity.
Article
Engineering, Multidisciplinary
Junichi Kouguchi, Hayato Yoshioka
Summary: A new monitoring method for milling process using signal analysis of acceleration sensors is proposed in this research, which can solve the difficulty in estimating cutting forces for small diameter tools.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Weijie Wang, Yanling Tian, Zhao Zhang, Zhilai Lu, Fujun Wang, Dawei Zhang
Summary: This paper proposes a comprehensive model for predicting the cutting depth and contact area in nanoscratching. The model takes into account the geometric shape of the indenter and elastic recovery, reducing prediction errors. The study also analyzes the influence of the indenter geometry on the contact area, with the face angle of the pyramid identified as a key factor.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Qiaolin Li, Yuki Shimizu, Xiaohao Wang, Xinghui Li, Wei Gao
Summary: This paper introduces a stitching linear scan method for roundness and diameter measurement of small cylinders, using a ruby ball stylus as hardware filtering to eliminate the influence of high-frequency data. Experimental results show that the repeatability of the ruby ball stylus is better than the diamond stylus.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Chaturaporn Kerdkaew, Surasak Kaewpho, Sakchai Chomkokard, Theera Yaemglin, Ittipon Cheowanish, Noparit Jinuntuya, Wiwat Wongkokua
Summary: A new calibration standard for a CMOS-based autocollimator using an optical angle generator with a submillimeter strip reflector (OAG-SSR) is proposed. This method provides angular values along the measuring range of the autocollimator without any mechanical movement, enabling a faster calibration process, which is suitable for integration with production lines.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Haohao Tao, Tongjie Li, Feng Chen, Jinwei Fan, Ri Pan
Summary: In this paper, a novel OTA method is proposed that considers the relationship between tolerance of machine tools' key parts and volumetric error. A volumetric error prediction model is established based on the bridge between geometric error and tolerance. Additionally, a Processing Simplicity Index (PSI) is introduced to replace manufacturing cost and a tolerance-PSI model is established. An OTA model is formulated to minimize volumetric error and maximize PSI. The feasibility and effectiveness of the method are validated through simulations and experiments.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Xiumin Zhang, Jianhua Liu, Huanxiong Xia, Xiaohui Ao, Jiechen Zhou, Zhihao Fu
Summary: A comprehensive finite-element model was developed in this paper to study the evolution of surface figure in high-precision bonded mirrors. The cure kinetics and mechanical behaviors of the optical adhesive were experimentally examined and modeled, and the effects of environmental factors on the surface-figure accuracy and stability were further investigated.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Peng Wang, Bin Chen, Jian Li, Jianwei Wang, Yingjie Zhang, Kai Feng
Summary: This paper proposes an aerostatic bearing with damper modules to suppress vibration on the bearing surface. The stiffness and damping characteristics can be adjusted by changing the thickness of the sheets, resulting in effective vibration suppression.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Lei Yang, Xiaoguang Guo, Renke Kang, Xianglong Zhu, Yufan Jia, Hao Wang
Summary: This paper develops an analytical model that takes into account the pad surface morphology to predict the evolution of the workpiece surface shape. The model considers the cross-scale relationship between the formation of lapped surface shape and the scratching process of a single abrasive grain. The simulated and experimental results validate the correctness and validity of the model, providing new ideas for controlling the workpiece surface.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Gabriele Piscopo, Alessandro Salmi, Eleonora Atzeni
Summary: This paper proposes an artifact for the LP-DED process and evaluates its dimensional accuracy and geometrical tolerances. The findings show that the tolerances of the LP-DED process are comparable to sand casting, lower than LB-PBF technologies, but similar to EB-PBF technologies.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Liang Xue, Ningsong Qu
Summary: This study focuses on the key issues of improving material removal rate and surface quality in macro-electrolyte jet machining. By introducing a novel tool with the rear-end tilted, the current density of the workpiece surface can be increased, leading to improved machining performance. Experimental results show that the tool with a rear-end tilt angle of 15 degrees significantly enhances the material removal rate and reduces surface roughness compared to the standard tool.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Ping Yang, Kaixin Luo, Runxi Wu
Summary: This article proposes a new calibration device to measure the spatial errors of a six-axis serial robot. The device compensates for errors by modifying angles and identifying stiffness parameters, and experiments verify its effectiveness.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Shilei Wu, Mingxiang Ling, Yingbin Wang, Tao Huang
Summary: This paper studies the electromechanical behavior of elliptical APAs by analyzing the multi-domain dynamics of piezoelectric stacks and compliant mechanisms using a novel electro-mechanical transfer matrix method. An analytical electro-elasto transfer matrix of piezoelectric stacks operating at the d33 mode is derived in the form of Taylor's series. The dynamic response spectrum of displacement and impedance for elliptical APAs is accurately captured by this electro-mechanical model, and different topologies of elliptical APAs are compared to suggest the optimal configuration.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Lei Meng, Yusheng Liu, Ying Yan, Dongming Guo, Ping Zhou
Summary: This study explores electrochemically induced chemical etching (ECICE) as a method to achieve nanogram-level, low-cost, stress-free, and stable material removal of fused quartz. The key factors affecting removal minimum and stability are revealed through modeling analysis and testing. A proposed method achieves precision stable removal with satisfactory results at the nanogram level.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Hong Yao, Hai Bi, Junjie Wei, Shuo Zhan, Fangxin Chen, IEEE
Summary: This paper presents a dual-loop control syringe-based picoliter-scale injection system for high-precision microinjection. The system utilizes an inner pneumatic servo loop and an outer position servo loop to achieve precise control. The experimental results demonstrate that the system can regulate the smallest droplet size to within 0.25 pL.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Jinchun Yuan, Jiasheng Li, Ye Ding
Summary: In this paper, a simple and effective internal model control (IMC) system is proposed to attenuate thrust ripples in ultraprecision air-bearing linear feed systems, based on a modified modeling and identification method of permanent magnet linear synchronous motors (PMLSMs). The performance of the proposed method in overcoming nonlinearity and achieving smooth velocities in steady states is demonstrated through analysis and experiments.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)