Abstract
In the paper, the concept of an electrochemically assisted microturning process is presented. This is a hybrid machining process in which microcutting directly removes the material while electrochemical passivation changes the conditions of material removal. A test stand was designed and built to investigate this process. The experimental part includes a discussion of the research methodology and a comparison of the straight turning results in the case of machining 1.4301 stainless steel without and with electrochemical assistance. The change of the main cutting force resulting from electrochemical assistance was selected as the main investigated technological factor. Based on this study, we can state that in the case analyzed here (when only passivation is taken into account), electrochemical assistance brings significant benefits when the depth-of-cut is ≤1 μm.
Article PDF
Similar content being viewed by others
References
Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32:153172
Brockhoff T, Brinksmeier E (1999) Grind-hardening: a comprehensive view. CIRP Ann - Manuf Technol 48(1):255–260
Cheng K, Huo D (eds) (2013) Micro-cutting: fundamentals and applications. Wiley
Davydov AD, Volgin VM, Lyubimov VV (2004) Electrochemical machining of metals: fundamentals of electrochemical shaping. Russ J Electrochem 40(12):1230–1265
Lauwers B (2011) Surface integrity in hybrid machining processes. Procedia Eng 19:241–251
Lauwers B, Klocke F, Klink A, Tekkaya AE, Neugebauer R, Mcintosh D (2014) Hybrid processes in manufacturing. CIRP Ann Manuf Technol 63(2):561583
Liu X, DeVor RE, Kapoor SG, Ehmann KF (2004) The mechanics of machining at the microscale: assessment of the current state of the science. J Manuf Sci Eng 126(4):666–678
Nagata M, Wakabayashi K, Yamada M, Masuzawa T (1999) Microcutting with reduced cutting force by electrolysis. J Jpn Soc Electr Mach Eng 33(74):24–31
Pham DT, Dimov SS, Bigot S, Ivanov A, Popov K (2004) Micro-edm - recent developments and research issues. J Mater Process Technol 149:50–57
Rajurkar KP, Sundaram MM, Malshe AP (2013) Review of electrochemical and electrodischarge machining. Procedia CIRP 6:13–26
Ramos AC, Autenrieth H, Strau T, Deuchert M, Hoffmeister J, Schulze V (2012) Characterization of the transition from plugging to cutting in micro machining and evaluation of the minimum thickness of cut. J Mater Process Technol 212(3):594–600
Ruszaj A, Skoczypiec S (2012) Combine electrochemical and electrodischarge microdetails shaping. In: Shore P, Spaan H, Bur T (eds) Proceedings of the 12th international conference of the European society for precision engineering and nanotechnology. euspen Headqarters, vol 2, Stockholm, pp 516–519
Shaikh JH, Jain NK (2014) Modeling of material removal rate and surface roughness in finishing of bevel gears by electrochemical honing process. J Mater Process Technol 214:200–209
Shaikh JH, Jain NK (2015) Effect of finishing time and electrolyte composition on geometric accuracy and surface finish of straight bevel gears in ech process. CIRP J Manuf Sci Technol 8:53–62
Skoczypiec S (2011) Research on ultrasonically assisted electrochemical machining process. Int J Adv Manuf Technol 52:565574. 24pkt
Skoczypiec S, Grabowski M, Ruszaj A (2013) Primary research on electrochemical assistance of microcutting process. In: Proceedings ot the 13th international conference of the European society for precision engineering and nanotechnology, vol II. EUSPEN, Berlin, pp 261–264
Skoczypiec S, Grabowski M, Spychalski M (2014) Experimental research on elelctrochemically asssisted microturning process. Key Eng Mater 611–612:701–707
Skoczypiec S, Ruszaj A (2014) A sequential electrochemicalelectrodischarge process for micropart manufacturing. Precis Eng 38:680690
Sun S, Brandt M, Dargusch MS (2010) Thermally enhanced machining of hard-to-machine materials a review. Int J Mach Tools Manuf 50:663680
Vollertsen F, Biermann D, Hansen HN, Jawahir IS, Kuzman K (2009) Size effects in manufacturing of metallic components. CIRP Ann - Manuf Technol 58(2):566–587
Wakabayashi K, Kawamata S , Yamada M, Tanaka T, Nagata M (1999) Micro cutting method and systems
Zhu D, Zeng YB, Xu ZY, Zhang XY Precision machining of small holes by the hybrid process of electrochemical removal and grinding. CIRP Ann - Manuf Technol:247250
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Skoczypiec, S., Grabowski, M. & Ruszaj, A. The impact of electrochemical assistance on the microturning process. Int J Adv Manuf Technol 86, 1873–1880 (2016). https://doi.org/10.1007/s00170-015-8320-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-8320-7