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Machining performance enhancement of deep micro drilling using electrochemical discharge machining under magnetohydrodynamic effect

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Abstract

Electrochemical discharge machining (ECDM) is a non-traditional machining technology used for micromachining of non-conductive materials including glass and ceramics. However, deep micro hole drilling (usually more than 500 μm) always encounters many problems, such as low repeatability, tool bending, and low machining efficiency. All these problems are mainly due to the bubble accumulation on the entrance hole. The phenomenon inhibits the electrolyte to enter the tip of the tool; therefore, the melting conditions will not be satisfied. The recent research shows that gas film formation and the motion of electrolyte are highly influenced by magnetohydrodynamic (MHD) effect. Further, the electrolyte circulation is improved by the MHD effect, and higher machining efficiency can be achieved. However, the poor electrolyte circulation in deep micro hole drilling is still exist, and the machining performance needs to be enhanced. In this paper, a simple, direct strategy for precisely tuning the machining parameters (i.e., supplied voltage and magnetic density) under MHD effect was introduced. Results show that the depth around 1000 μm can be achieved within 100 s with quite good surface quality and even deeper micro hole can be achieved. The method using MHD effect brings a great potential for the development of feedback control algorithms for micro hole machining.

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Data availability

All data generated or analyzed during this study are included in this published article.

Abbreviations

Fb :

Buoyancy force

Fs :

Surface tension

Fl :

Lorenz force

ρ g :

Density of hydrogen gas

ρ l :

Density of electrolyte

ρ :

Concentration of dissolved hydrogen

ρ 0 :

Bulk flow density of the electrolyte

\( \overrightarrow{B} \) :

Magnetic field

\( \overrightarrow{I} \) :

Current field

V:

Velocity vector of the electrolyte

D:

Diffusion coefficient of the dissolved hydrogen

n:

Electrode normal direction

z:

Discharge number

F:

Faraday constant

P:

Pressure of the electrolyte

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Funding

This research was supported by the national program for Key S & T project (2014ZX04009021) China, China Postdoctoral Science Foundation Funded Project (No. 2020M672332), and advanced programs of Hubei human resources and technology (No. 016100200). The author also would like to gratefully acknowledge the financial support from China Scholarship Council.

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Authors and Affiliations

  1. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, China

    Yi Xu

  2. Mechanical Engineering, University of Michigan, Ann Arbor, MI, USA

    Yi Xu & Baoyang Jiang

Authors
  1. Yi Xu
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  2. Baoyang Jiang
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Contributions

Yi Xu and Baoyang Jiang conceived the idea. Yi Xu built up the experimental platform and was the major contributor in writing the manuscript. Baoyang Jiang provided valuable suggestions and improved the English writing.

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Correspondence to Yi Xu.

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Xu, Y., Jiang, B. Machining performance enhancement of deep micro drilling using electrochemical discharge machining under magnetohydrodynamic effect. Int J Adv Manuf Technol 113, 883–892 (2021). https://doi.org/10.1007/s00170-021-06657-8

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