Abstract
Fabrication of the injection nozzle micro-hole on the aero engine is a difficult problem in today’s manufacturing industry. In addition to the size requirements, the nozzle micro-hole also requires no burr, no taper and no heat-affected zone. To solve the above problem, an ultra-short voltage pulse and a high-speed rotating helical electrode were used in electrochemical drilling (ECD) process. Firstly, a theoretical model of ECD with ultra-short voltage pulse was established to investigate the effects of many predominant parameters on machining accuracy, and the effect of rotating helical electrode on the gap flow field was analyzed. Secondly, sets of experiments were carried out to investigate the effects of many key parameters on machining accuracy and efficiency. Finally, the optimized parameters were applied to machine micro holes on 500 μm thickness of GH4169 plate, and micro-holes with the diameter of 186 μm with no taper were machined at the feed rate of 1.2 μm/s. It is proved that the proposed ECD process for fabricating micro-holes with no taper has a huge potential and broad application prospects.
Highlights
With the development of micro electro-mechanical system (MEMS), the demand for micro components is increasing [1]
The quality of micro holes is determined by the machining accuracy, taper of holes and the machining efficiency
The helical electrode can be rotated driven by the motorized spindle, whose
Summary
With the development of micro electro-mechanical system (MEMS), the demand for micro components is increasing [1]. Wu et al. Micromachinesa2019, 10, 28 desktop micro electro-chemical machining (ECM) and fabricated micro-holes developed low-cost in the tungsten cemented carbide (WC-Co) workpiece with spindle electrode [22]. Takingelectrode advantage of single rotaryinhelical process to improve the machining accuracy, decrease the taper of holes, and improve the machining electrodes in the process of ECD can enhance the maximum feed rate, and the maximum feed rate can be efficiency. The theoretical modelspeed was established and were carried outimproved to investigate the improved by increasing rotating [18,19,20,21], theexperiments machining efficiency can be by using influence of many predominant on athe machining drilling process. Developed low-cost desktop micro electro-chemical machining micro array holes were fabricated efficiently applying the optimized parameters. Experimental system consists of various drilling sub-components, e.g., electrodes unit, influence of manyThe predominant parameters on the machining process.
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