Skip to main content
SpringerLink
Log in

Effect of structural parameters of array of holes in the tube electrode for electrochemical cutting

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Wire electrochemical machining is a highly flexible machining method based on the electrochemical dissolution of a workpiece anode, which corrodes. Material is removed locally from the workpiece as the tool is moved through two dimensions. In electrochemical cutting using a tube electrode, a metal tube with an array of holes on the sidewall replaces the conventional wire as the tool cathode. The electrolyte enters through the top of the tube electrode, is ejected though the array of holes, and directly sprays onto the machining surface of the workpiece. In this paper, the flow of the electrolyte in the machining gap was simulated for tube electrodes with different holes spacing and inclination angles. Experiments verified that the refreshment of the electrolyte and the removal of electrolysis products were fast and the machining efficiency was high when the holes spacing was 1 mm and inclination angle was −45°. Adding supplementary electrolyte into the slit improves the consistency of the slit width. Finally, using the optimized structural parameters, arrays of columns were fabricated from 10-mm-thick stainless steel 304 at a feed rate of 7 μm/s.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

References

  1. Rajurkar KP, Zhu D, McGeough JA, Kozak J, De SA (1999) New developments in electro-chemical machining. CIRP Ann - Manuf Technol 48:567–579

    Article  Google Scholar 

  2. Niu S, Qu NS, Fu SX, Fang XL, Li HS (2017) Investigation of inner-jet electrochemical milling of nickel-based alloy GH4169 / Inconel 718. Int J Adv Manuf Technol 93:2123–2132

    Article  Google Scholar 

  3. Sharma V, Srivastava I, Jain V, Ramkumar J (2019) Modelling of wire electrochemical micromachining (wire-ECMM) process for anode shape prediction using finite element method. Electrochim Acta 312:329–341

    Article  Google Scholar 

  4. Saxena KK, Qian J, Reynaerts D (2018) A review on process capabilities of electrochemical micromachining and its hybrid variants. Int J Mach Tools Manuf 127:28–56

    Article  Google Scholar 

  5. Debnath S, Kundu J, Bhattacharyya B (2017) Influence of wire electrochemical machining parameters during fabrication of micro features. Int J Precis Technol 7:103–118

    Article  Google Scholar 

  6. Debnath S, Doloi B, Bhattacharyya B (2019) Review—wire electrochemical machining process: overview and recent advances. J Electrochem Soc 166:E293–E309

    Article  Google Scholar 

  7. Sharma S, Jain V, Shekhar R (2002) Electrochemical Drilling of Inconel Superalloy with acidified sodium chloride electrolyte. Int J Adv Manuf Technol 19:492–500

    Article  Google Scholar 

  8. Jiang K, Wu XY, Lei JG, Wu W, Li W, Diao DF (2018) Vibration-assisted wire electrochemical micromachining with a suspension of B4C particles in the electrolyte. Int J Adv Manuf Technol 97:3565–3574

    Article  Google Scholar 

  9. Xu K, Zeng YB, Li P, Zhu D (2015) Study of surface roughness in wire electrochemical micro machining. J Mater Process Technol 222:103–109

    Article  Google Scholar 

  10. Fang XL, Zou XH, Zhang PF, Zeng YB, Qu NS (2016) Improving machining accuracy in wire electrochemical micromachining using a rotary helical electrode. Int J Adv Manuf Technol 84:929–939

    Google Scholar 

  11. He HD, Qu NS, Zeng YB, Fang XL, Yao YY (2016) Machining accuracy in pulsed wire electrochemical machining of γ-TiAl alloy. Int J Adv Manuf Technol 86:2353–2359

    Article  Google Scholar 

  12. Yang T, Zeng YB, Hang YS (2019) Workpiece reciprocating movement aided wire electrochemical machining using a tube electrode with an array of holes. J Mater Process Technol 271:634–644

    Article  Google Scholar 

  13. Xu K, Zeng YB, Li P, Fang XL, Zhu D (2016) Effect of wire cathode surface hydrophilic when using a travelling wire in wire electrochemical micro machining. J Mater Process Technol 235:68–74

    Article  Google Scholar 

  14. He HD, Qu NS, Zeng YB, Tong PZ (2017) Improvement of hydrogen bubbles detaching from the tool surface in microwire electrochemical machining by applying surface microstructures. J Electrochem Soc 164:E248–E259

    Article  Google Scholar 

  15. Zou XH, Fang XL, Chen M, Zhu D (2018) Investigation on mass transfer and dissolution localization of wire electrochemical machining using vibratory ribbed wire tools. Precis Eng 51:597–603

    Article  Google Scholar 

  16. Meng LC, Zeng YB, Zhu D (2018) Helical carbon nanotube Fiber tool cathode for wire electrochemical micromachining. J Electrochem Soc 165:E665–E673

    Article  Google Scholar 

  17. Fang XL, Zhang PF, Zeng YB, Qu NS, Zhu D (2016) Enhancement of performance of wire electrochemical micromachining using a rotary helical electrode. J Mater Process Technol 227:129–137

    Article  Google Scholar 

  18. Zou XH, Fang XL, Zeng YB, Zhu D (2017) A high efficiency approach for wire electrochemical micromachining using cutting edge tools. Int J Adv Manuf Technol 91:3943–3952

    Article  Google Scholar 

  19. Klocke F, Herrig T, Zeis M, Klink A (2018) Experimental investigations of cutting rates and surface integrity in wire electrochemical machining with rotating electrode. Procedia CIRP 68:725–730

    Article  Google Scholar 

  20. Klocke F, Herrig T (2018) Klink a (2018) evaluation of wire electrochemical machining with rotating electrode for the manufacture of fir tree slots. Proc ASME Turbo Expo 6:1–6

    Google Scholar 

  21. Zeng YB, Yu Q, Fang XL, Xu K, Li HS, Qu NS (2015) Wire electrochemical machining with monodirectional traveling wire. Int J Adv Manuf Technol 78:1251–1257

    Article  Google Scholar 

  22. Qu NS, Fang XL, Zhang YD, Zhu D (2013) Enhancement of surface roughness in electrochemical machining of Ti6Al4V by pulsating electrolyte. Int J Adv Manuf Technol 69:2703–2709

    Article  Google Scholar 

Download references

Funding

This project was supported by the National Natural Science Foundation of China (51975291), the Natural Science Foundation of Jiangsu Province (BK20192007), and the Postgraduate Research & Practice Innovation Program of Jiangsu Province (KYCX19_0167).

Author information

Authors and Affiliations

  1. Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Tao Yang, Yongbin Zeng, Yumeng Sang & Shouye Li

Authors
  1. Tao Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yongbin Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yumeng Sang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shouye Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yongbin Zeng.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yang, T., Zeng, Y., Sang, Y. et al. Effect of structural parameters of array of holes in the tube electrode for electrochemical cutting. Int J Adv Manuf Technol 107, 205–216 (2020). https://doi.org/10.1007/s00170-020-05089-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05089-0

Keywords

Search

Navigation