Abstract
Electrochemical cutting using tube electrode with inclined holes is a machining method that directly and obliquely injects electrolyte into the machining gap through inclined jet-flow holes on the sidewall of a tube electrode, allowing the electrochemical cutting of a workpiece. To improve the machining efficiency and accuracy of this cutting technique, a method of workpiece vibration in feed direction–assisted electrochemical cutting is proposed in which workpiece vibration rapidly and periodically changes the machining gap. The near-instantaneous increases in the machining gap promote the renewal of electrolyte and the removal of electrolytic products. At the same time, the electrochemical reaction time under the nonuniform flow field caused by the inclined downward injection of electrolyte is reduced. The flow field simulation of electrolyte in machining gap indicates that the near-instantaneous increases in the machining gap can improve the flow velocity of electrolyte. The effect of the vibrational amplitude and frequency on the machining result is investigated by cutting slit experiments. Compared with that of electrochemical cutting without workpiece vibration in feed direction, the average feed rate of electrochemical cutting assisted by workpiece vibration with amplitude of 0.1 mm and frequency of 1.5 Hz can be increased by 50%, and the width difference between the upper and lower end of the slit is reduced from 115.56 to 49.6 μm. The machining efficiency and machining accuracy of electrochemical cutting using tube electrode with inclined holes are improved. Finally, an array slice structure is fabricated on a stainless steel block with a cross-section of 10 mm × 10 mm at average feed rate of 6 μm/s using a vibrational amplitude and frequency of 0.1 mm and 1.5 Hz, respectively.
Highlights
With the emergence of various difficult-to-machine materials and their application in aerospace, precision instruments, die manufacturing, and other fields, more stringent requirements are being imposed on the efficiency and accuracy of mechanical processing
Experiment demonstrates that the average feed rate can be increased by 50% and the machining efficiency is superior to that of electrochemical cutting assisted by workpiece non-vibration in feed direction
In the process of electrochemical cutting assisted by workpiece vibration in feed direction, the maximum movement speed of X-axis is 6 μm/s, and the machining efficiency is higher, which is increased by 50% compared with that of electrochemical cutting assisted by workpiece non-vibration in feed direction
Summary
With the emergence of various difficult-to-machine materials and their application in aerospace, precision instruments, die manufacturing, and other fields, more stringent requirements are being imposed on the efficiency and accuracy of mechanical processing. Upward and downward reciprocating movement of the workpiece was found to induce a fluid flow in the electrolyte that aids the removal of electrolytic products With this technique, a micro-gear structure was fabricated on an amorphous material, namely nickel-based metallic glass, at a feed rate of 0.5 μm/s [11]. For the electrochemical cutting of thick workpieces, Volgin et al [13] performed simulations that examined whether rotation or reciprocating movement of the cathode assisted electrochemical cutting and improved machining efficiency, especially if an electrode with a noncircular (e.g., square or triangular) cross-section was adopted It has been found [14] that using a ring of metal wire under unidirectional movement as the cathode drags the electrolyte, facilitating the rapid removal of electrolytic products and the refreshment of the electrolyte. To improve the machining efficiency and reduce the difference between the upper and lower slit widths, a method of workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined jet-flow holes is proposed. An array slice structure is fabricated on a stainless steel block with a cross-section of 10 mm × 10 mm at average feed rate of 6 μm/s using a vibrational amplitude and frequency of 0.1 mm and 1.5 Hz, respectively
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callMore From: The International Journal of Advanced Manufacturing Technology
Disclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
