This paper presents an overview of the current technological and economical capabilities of electrochemical (ECM-based), electro-physical (EDM-based) and photonic (Laser-/EBM-based) additive and removal processes for turbomachinery component manufacture. Starting with the industrial demands and challenges of today, the technologies are reviewed in detail regarding achievable geometrical precision and surface integrity as well as material removal and deposition rates for conventionally difficult-to-cut Ti- and Ni-based alloys and dedicated steels. Past, existing and future areas of technology application of these advanced non-mechanical manufacturing processes are discussed. The paper focusses on the description of shaping processes therefore excludes pure welding or coating applications.

Turbomachinery component manufacture by application of electrochemical, electro-physical and photonic processes

The electrochemical micromachining in non-conventional machining which suffers from process control in micro level. In addition, the work material i.e. stainless steel provides high strength, high toughness and adherence to tool material, hence machining of such material is arduous. However, the use of stainless steel offers its availability in the field of aerospace fuel injection and orthodontic application, since it possess superior qualities. In this paper, the optimization of micro drilling process is carried out in stainless steel by considering certain metrics like feed rate, voltage and duty ratio. The geometric characteristics to drill the tool depends on response parameters like overcut, removal rate of material and conicity. Such parameter determines both the geometric and machining characteristics of the drill bit. The study is evaluated to observe the effect of response and duty ratio parameters such as material removal rate (MRR), machining time and overcut. Further, the conicity is analyzed using VMS images. Finally, the proposed work establishes duty cycle in pulsed electrochemical micromachining domain of hard materials and tests its performance.

Experimental investigation of machined hole and optimization of machining parameters using electrochemical machining

https://ro.uow.edu.au/cgi/viewcontent.cgi?article=1759&context=eispapers1

A review of modern advancements in micro drilling techniques

Study of surface integrity and dimensional accuracy in EDM using Fuzzy TOPSIS and sensitivity analysis

Technology development has led to the need of micro and miniaturized products in the field of automobile, aerospace, electronics, medical implants, biomedicine, robotics, and so on. Micromachining is the key technology to satisfy the need of the industry in terms of functionality and miniaturization in size. In this article, state-of-the-art review on tool-based micromachining processes such as microturning, microdrilling, micromilling, electric discharge micromachining (Micro-EDM), and electrochemical micromachining (Micro-ECM) has been carried out. The review begins with an overview of micromachining, classifications, and discussions about different aspects of tool-based micromachining processes. The research works carried out for the past 10 years are analyzed in terms of materials perspective, process parameters, size effects, performance characteristics, condition monitoring, product development, micro features generation, and fabrication of micro tools. A statistical analysis has been performed with...

A Review on Current Research Aspects in Tool-Based Micromachining Processes

The application of Infrared (IR) light in electrochemical micromachining (EMM) is to focus the machining to confined areas so that material removal and productivity is improved. Predominantly, the localization mechanism in electrochemical machining (ECM) for material removal is determined by the temperature. In this study, a novel method of heating the electrolyte using IR has been attempted in EMM for the first time. IR light is considered for indirect heating of sodium nitrate (NaNO3) electrolyte. Machining parameters such as machining voltage, duty cycle, and electrolyte concentration are varied by keeping the current and electrolyte temperature constant at 1 A and 37 ± 0.5°C, respectively. The effect of these parameters on machining rate and overcut is studied. The result showed that the machining rate for heated electrolyte is 4.2 times better than the electrolyte at room temperature for 25% duty cycle, 35 g/L electrolyte concentration, and 9 V machining voltage. The change in electrolyte con...

Performance of electrochemical micromachining of copper through infrared heated electrolyte

Electrochemical Micromachining of Stainless Steel with Acidified Sodium Nitrate Electrolyte

Miniaturization in all emerging areas is rapidly increasing. To meet this need, micromachining is considered as one of the key technologies for the production of miniaturized parts and components. ...

Experimental Study on the Influence of Tool Electrode Tip Shape on Electrochemical Micromachining of 304 Stainless Steel

This paper describes Electrochemical Micromachining (EMM) of stainless steel with acidified sodium nitrate. The sulphuric acid of 0.05m/L is added to the standard electrolyte namely sodium nitrate to solubilise the by-products. The foremost characteristics of EMM are researched through scheme of experiments involving various parameters, such as machining voltage, pulse on time and electrolyte concentration. The performance of acidified sodium nitrate and sodium nitrate on EMM are compared. Based on the study, the machining rate and overcut are significantly improved using acidified sodium nitrate as an electrolyte. © 2013 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Bert Lauwers Keywords: Acidified sodium nitrate; Electrolyte; Overcut; Machining rate . 1. Introduction Since the increase in the demand for micro components/products, micromachining technology has gained an important place in the fabrication of miniaturized products [2]. Among the micro electrical manufacturing technologies, EMM is one of the promising technologies that are gaining importance for its advantages such as stress-free, with good surface finish and the ability to machine complex structures in metallic materials, regardless of their hardness, high strength, or heat-resistant [5]. Researchers have already initiated the research in electrochemical micromachining. Recently, a significant breakthrough in micro ECM was presented by Ryu (2009) and micro ECM has been a key subject to the related researchers. Using environmentally friendly electrolyte of citric acid, they have made micro holes of 60μm in diameter with the depth of 50μm and 90μm in diameter with the depth of 100μm. Bao Huaiqian et al. (2008) machined trilateral and square cavities and holes as well as a group of English alphabets on a stainless steel plate using pure water as an electrolyte. Ye Yang et al. (2011) have fabricated micro pins and micro holes using everyday mineral water as an electrolyte. Sharma et al. (2002) machined holes in inconel super alloy that is used for turbine blades with acidified neutral salt electrolyte to minimize sludge formation in the Inter Electrode Gap (IEG). They obtained a good and uniform hole with an aspect ratio of 11. Lee et al. (2002) have applied two electrolytes, aqueous sodium nitrate and aqueous sodium chloride. The study reveals that the former electrolyte has better machinability than the latter. Mithu et al. (2011) have used less toxic and dilute electrolyte, 0.2 M HCl for microholes fabrication. The acidic electrolyte allowed refreshing electrolyte in the machining area easily, due to the reason that acid electrolyte usually

The Seventeenth CIRP Conference on Electro Physical and Chemical Machining (ISEM) Electrochemical micromachining of stainless steel with acidified sodium nitrate electrolyte

Tri-layer hybrid composites composed of Indian almond and kenaf fibers were fabricated using hand layup method. Two types of hybrid composites namely Kenaf/Indian almond/Kenaf (K/I/K) and I...

Experimental Investigation on Mechanical and Biodegradation Properties of Indian Almond–Kenaf Fiber-Reinforced Hybrid Composites for Construction Applications

R. Thanigaivelan

Papers

Performance of electrochemical micromachining of copper through infrared heated electrolyte

Electrochemical Micromachining of Stainless Steel with Acidified Sodium Nitrate Electrolyte

Experimental Study on the Influence of Tool Electrode Tip Shape on Electrochemical Micromachining of 304 Stainless Steel

The Seventeenth CIRP Conference on Electro Physical and Chemical Machining (ISEM) Electrochemical micromachining of stainless steel with acidified sodium nitrate electrolyte

Experimental Investigation on Mechanical and Biodegradation Properties of Indian Almond–Kenaf Fiber-Reinforced Hybrid Composites for Construction Applications