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Abstract
Electrochemical discharge machining (ECDM) is an emerging special processing technology for non-conductive hard and brittle materials, but it may encounter the problem of tool wear due to its process characteristics, which affects the processing accuracy. In this study, in the non-machining state, the tungsten carbide spiral cathode with a diameter of 400 μm was selected to analyze the influencing mechanism of the process parameters on tool wear, and a suitable voltage range for the processing was obtained. The influence of the cathode’s loss behavior on the film formation time and the average current of spark discharge was discussed based on the current signal. The results show that the tool wear mainly appears from the bottom to the end and edge tip of the protrusion. Loss is mainly in the form of local material melting or gasification at high temperature. In addition, the loss may shorten the film formation time, but the effect on the average current of spark discharge is small.
Highlights
Electrochemical discharge machining (ECDM) is an emerging special processing technology, which has the advantages of high efficiency, good flexibility and low cost [1,2,3,4]
In the ECDM drilling test for carbon fiber-reinforced polymer (CFRP), the factors which affect the machining precision are from various aspects, including tool wear, the stability of gas film, the electrolyte components and the CFRP machining process
In ECDM, alkaline solution is usually used as the electrolyte
Summary
Electrochemical discharge machining (ECDM) is an emerging special processing technology, which has the advantages of high efficiency, good flexibility and low cost [1,2,3,4]. It can be used to handle non-conductive hard and brittle materials with fine structure [5,6]. With the development of micro-electromechanical system (MEMS) and microfluidics technologies, higher technical requirements are raised for the microfabrication of non-conductive materials, such as glass, ceramics, and carbon fiber-reinforced polymer (CFRP) material. ECDM has rapidly developed and been studied as an important processing method [7,8,9]. For the micro-machining of hard and brittle material with complicated 3D structures, many studies have been conducted to improve the machining precision, such as changing the motion control approach [10], parameter optimization using the response surface method [11] and building the tool wear simulation model [12]. In the ECDM drilling test for CFRP, the factors which affect the machining precision are from various aspects, including tool wear, the stability of gas film, the electrolyte components and the CFRP machining process
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