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Thin-walled micro-holes are frequently used in aerospace components to achieve specific functions, such as heat dissipation and filtration. However, traditional manufacturing technologies face difficulties in achieving precision machining of these holes due to deformation caused by cutting force or heat. Laser machining is a highly flexible and efficient advanced processing technology that aims to achieve precise machining of thin-walled holes. However, it is important to note that the thermal energy generated by the laser can cause deformation of the thin walls. To address these issues, this paper proposes a process that combines laser and backside electrochemical composite machining. The model for laser electrochemical composite processing after through-hole formation suggests that the laser's temperature rise effect on the electrolyte can significantly enhance the efficiency of electrochemical processing. Furthermore, the laser exerts a micro-zone stirring effect on the electrolyte in the processed micro-zone, which promotes the liquid-phase mass transfer process during the electrochemical reaction. Furthermore, a one-way experiment was conducted to investigate the effects of the main laser parameters on the processing results. The results indicated that higher laser power, as well as lower laser frequency and scanning speed, significantly reduced the edge damage and pore taper of the processed micro-holes. The language used is clear, concise, and objective, adhering to a formal register and avoiding biased or ornamental language. Technical terms are consistently used and explained when first introduced. The text is grammatically correct and free from spelling and punctuation errors. Furthermore, this process has significantly reduced the oxygen content and surface roughness of the sidewalls of the micro-holes. [ABSTRACT FROM AUTHOR]

The potential of micro electrochemical slotting is significant due to its adaptability and usefulness across diverse manufacturing applications. This technique holds potential, particularly for handling advanced engineering materials like superalloys, with a focus on applications requiring high strength, i.e., micro-cutting for gas-turbine parts, biomedical applications, etc. With this view, this article has been attempted to explore the influence of various considered machining factors, namely as; applied potential difference, tool feed rate (TFR), pulse supply, and modes of tool insulation on the performance measures, i.e. material removal rate (MRR) and surface roughness (Ra) while attempting micro-slotting in Nimonic-263 superalloy work samples. The entire experimentation was conducted on the in-house fabricated 3-axis micro-electrochemical setup designed for performing various complex machining operations at a miniature scale. Furthermore, this study has also been focused toward investigating the impact of varying the electrical conductivity by employing different tool materials (i.e. copper and SS304) on the process characteristics measured. The observed effects of the tool electrode's conductivity have also been expressed and supported by performing the simulation for electric field distribution using COMSOL Multiphysics software. The experimental results have revealed that the process input variables remarkably influence MRR and Ra, mainly applied voltage and TFR. The best values of MRR and Ra attained with SS304 and copper tool electrodes were 1.521 mg/min and 0.721 mg/min, and 0.038 µm and 0.029 µm, correspondingly. The microstructure analysis has further been conducted on machined micro-slotted work samples that provided detailed insights into various surface integrity aspects, which are essential for microdevice applications. [ABSTRACT FROM AUTHOR]

The removal of metal in the form of sludge can be termed an ECM process, having primary salient features consisting of the tool, workpiece, power supply and electrolyte solution. ECM is a potential nontraditional machining process that includes too many factors contributing to process performance. Therefore, obtaining optimal factor combinations for higher efficiency is complex. In this research work, machining parameters are voltage, powder concentration and electrolyte concentration, based on which material removal rate (MRR) and surface roughness (SR) are derived. Regression analysis, signal-to-noise ratios and analysis of variance (ANOVA) are performed to determine the optimal levels and to examine the effects of machining parameters on MRR and SR. The results derived from the experiments noticed that the MRR decreases when the voltage level is increased and surface roughness decreases for the applied voltage. In case of an increase in powder concentration, MRR decreases from range 4 to 6 and further reduces to 6–8. In case of SR, it additionally decreases on the maximum level of powder concentration. In electrolyte concentration, the MRR decreases on the increment of electrolyte and increases after a short period of time; simultaneously SR is increased from range value 10–20 and decreased with a maximum level 20–30 of NaCl solution. A comparison of MOORA-PCA and TOPSIS-PCA demonstrates the superiority of TOPSIS over MOORA technique. Statistical results (95% confidence level) indicate that the voltage, powder concentration, and electrolyte concentration affect the surface roughness by 69.50%, 8.67% and 14.59% in the electrochemical machining of d3 die steel. Therefore, the optimum combination of process parameters corresponding to voltage: 45 V, powder concentration: 4 g/L, and electrolyte concentration: 10 NaCl/L, respectively, were found to yield the desired result. The prediction accuracy of the TOPSIS-PCA hybrid approach model is found better than MOORA-PCA technique. [ABSTRACT FROM AUTHOR]

Glass is a widely used material in key fields such as Micro-Electro-Mechanical Systems (MEMS) due to its excellent properties. The existing non-traditional glass machining methods have problems such as high pollution, difficult operation, and poor sustainability, this article utilizes the effective combination of electrochemical discharge machining and grinding (named electrochemical discharge grinding, ECDG), by using NaHCO 3 solution as electrolyte to achieve green machining. Utilizing ultrasonic vibration and multi-hole tube electrode to achieve precise and stable machining. Modeling and simulation analysis were conducted on the material removal rate and grinding force during the machining process, which profoundly revealed the joint improvement mechanism of spark discharge and ultrasonic vibration on grinding quality. First, a single factor experiment was used to preliminarily determine the machining threshold. Second, the Plackett-Burman experiment was used to screen key machining parameters. Then, Box-Behnken experiment was conducted on key machining parameters, and multi-objective and multi-factor optimization was performed to obtain the optimal combination of machining parameters. Compared with normal ECDG with cylindrical grinding electrode, the overcut is reduced by 8.3 %, the edge damage is reduced by 17.5 % and the surface roughness value is reduced by 70.6 %. Finally, by using the optimized combination of machining parameters, high-quality and stable machining of typical microchannel structures was achieved. The milling depth of the microchannel is 400 µm. The machining width is 1175 ± 5 µm. The surface roughness of the measurement area is 0.375 µm. The green, high-quality and stable machining of micro glass micro components further demonstrates the potential application of this compound technology. [Display omitted] [ABSTRACT FROM AUTHOR]

This article presents a review on some important recent research, development, and innovations related to the nonconventional machining of glass material. Nonconventional machining processes were identified suitable for machining of glass, years ago, and from then to now various technological developments have made nonconventional machining a viable alternate to the conventional machining of glass material. In this article, we have mainly focused on three important nonconventional machining processes, namely, last cutting, ultrasonic machining, and electrochemical discharge machining (ECDM). Novel aspects, effects of process parameters, and salient features are discussed. Mainly, previous five years' work is reviewed. This review finally ends with a conclusion and important future research directions. [ABSTRACT FROM AUTHOR]

Electrochemical machining (ECM) offers a superior technology for manufacturing hard-cutting metals such as modified Inconel 718 (IN718). However, in many cases, poor surface quality arises because of the specific dissolution characteristics of the material, hindering further application of the process. Vibration-assisted ECM (VA-ECM) has been proposed in the hope of solving the problem by oscillating the cathode. A multiphysics model was developed for pulsed ECM (PECM) and VA-ECM. Systematic experiments were performed to clarify the mechanism of cathode oscillation on surface quality and verify the computational results. With 20 Hz vibration frequency and 25% duty cycle, the surface roughness reaches 0.39 µm, show that higher oscillation frequency and lower duty cycle are effective in improving surface quality. Finally, dissolution models of modified IN718 under PECM and VA-ECM are proposed. By oscillating the cathode, electrolyte fluctuation is enhanced, electrolytic products are removed effectively, the surface quality is improved significantly. [ABSTRACT FROM AUTHOR]

Electrochemical machining (ECM) is one of the most ideal machining methods for difficult-to-cut material of U71Mn alloy. Therefore, it is vital to obtain the electrochemical characteristics of the material. In this paper, these characteristics are measured with an electrochemical station, and a series of experiments are conducted to verify them. The electrolyte solutions of 15 wt.% NaNO3 and 15 wt.% NaCl are selected for the experiments. The polarization experimental results indicate a broader range of passive regions in the NaNO3 electrolyte solution compared with that in the NaCl. This means that a higher voltage is required to break down the passive film in ECM experiments. Meanwhile, the current efficiency of the alloy is measured in 15 wt.% NaNO3 and 15 wt.% NaCl. The results indicate that the current efficiency of U71Mn alloy in NaCl electrolyte solution is higher than that in NaNO3 electrolyte solution. The electrochemical characteristics of U71Mn alloy are verified with a series of single-factor experiments, and reasonable machining parameters are obtained. The suitable range of machining voltage is 10 to 20 V, and the range of inter-electrode gap is 0.1 to 0.2 mm in these two electrolyte solutions. Finally, multi-parameter experiments are carried out in these two electrolyte solutions to obtain machining samples. The experimental results show that 15 wt.% NaNO3 proved to be a better electrolyte solution for U71Mn alloy, the surface roughness (SR) of the workpiece is Sa 0.72 μm, and the material removal rate (MRR) is 0.096 g/min. [ABSTRACT FROM AUTHOR]

Electrochemical machining (ECM) technology holds significant potential for applications in high accuracy engineering and manufacturing. To confine the electrolyte region during ECM and mitigate the effects of reaction products and heat generation, an electrolyte suction tool has been proposed. However, the complex electric field distribution on the anode surface during the application of pulse voltage, limits the further utilization of ECM with suction tool. A multi-physics simulation model is established to calculate the region of electrolyte confinement by the suction tool, current density distribution within the electrolyte region, and material removal. The model considers the combined effects of polarization and double layer, and all key parameters are calibrated through classical electrochemical testing experiments rather than fitted based on the predicted results. This study elucidates the transient response of current density on the anode surface during the application of pulse voltage. The simulation accuracy is validated by comparing experimental and simulated current waveforms, as well as material removal profiles under different pulse parameters and electrode shapes. This research is of great significance for improving surface precision and controllability of complex structures in ECM with suction tool, promoting its further application in the field of precision machining. • Establish a multi-physics field coupled simulation for ECM with electrolyte suction tool. • Calibrate all key parameters through classical electrochemical testing experiments. • Elucidate the transient response of Faraday current density on the anode surface during pulse voltage. • Elucidate the material removal mechanism under the combined effects of polarization and double layer. [ABSTRACT FROM AUTHOR]

Bulk metallic glasses (BMGs) have excellent mechanical properties, however, it is still challenging to process high-qualtiy BMG structures for their widespread engineering applications. In this work, electrochemical machining (ECM) is adopted to process various small BMG structures with high geometrical precision and surface quality. Firstly, the electrochemical dissolution behavior of a Zr 57 Cu 20 Al 10 Ni 8 Ti 5 (at.%) BMG in NaNO 3 , H 3 PO 4 , NaCl, and HCl solutions was investigated and discussed. The results shown that obvious corrosion occurred in HCl and NaCl solutions, while mass by-products and pitting corrosion on the workpiece surface in NaCl solution affect the corrosion continuity and surface quality. Therefore, the HCl solution is selected as the electrolyte for the following ECM process. Secondly, the effects of machining parameters on the ECM performance of BMG workpieces were investigated, where the optimal machining performance was achieved with an electrolyte of 0.1 mol/L HCl, a cathode feed rate of 3 μm/s, a machining voltage of 10 V, and a duty cycle of 15%. Finally, a small round hole with a roughness (Ra) of about 0.2 μm, a sidewall taper of less than 2.83°, and a relative error of diameters of 2.1% was obtained. Another square structure (0.899 mm × 0.891 mm) with high geometrical precision and surface quality was also achieved by the optimal parameters, which validates the feasibility to machine small BMG structures using the ECM technique with its optimal parameters. [Display omitted] • The electrochemical dissolution behavior in four solutions was investigated. • HCl solution was selected as a suitable electrolyte for the ECM process. • The effects of machining parameters on ECM performance were investigated. • Optimal processing parameters for the ECM of Zr57 BMG were obtained. • Typical small BMG structures were fabricated. [ABSTRACT FROM AUTHOR]

Thin-walled annular parts are widely used in the aerospace industry. There are some irregular island structures with non-periodic distribution on the inner surfaces of annular parts, which poses a significant challenge to manufacture such annular parts using conventional mechanical methods. Electrochemical machining (ECM) has exhibited good prospects for manufacturing thin-walled annular parts, with the advantages of no tool wear, no processing deformation and a high material removal rate. However, there is little research related to fabricate convex structures on the inner surfaces of annular parts, although ECM is vital to the machining of thin-walled annular parts. In this study, a flexible cathode tool was used to machine irregular convex structures on the inner surfaces of annular parts via co-rotating ECM. The complex motion of the cathode tool and conductive slider was simulated using matrix equations, and the digital simulation of the material removal process was realized based on matrix equations and Faraday's law. Based on the mathematical model, a design method for a flexible cathode tool was developed, and three main parameters were determined: the position of the window, radius of the cathode, and width of the window. Comparative experiments were performed using the flexible and conventional cathode tools. The results showed that the selective removal of convex structures was achieved by using the flexible cathode tool. The insulated sheet needed to be attached to the position where the convex structure was retained. An aero-engine casing with many irregular island structures on the inner surface was successfully machined. The height of the fabricated island structure is 6 mm. The sidewall thickness of the aero-engine casing is 1.2 mm. Therefore, co-rotating ECM with a flexible cathode tool offers excellent machining ability for irregular island structures on the inner surfaces of annular parts. [Display omitted] • Co-rotating electrochemical machining using a flexible cathode tool is proposed to machine structures on the inner surface of annular parts. • Based on the mathematical model of the material removal process, a design method for a flexible cathode tool is proposed. • The selective retention of island structures is achieved by adding a movable conductive slider in a conventional cathode window. • An aero-engine casing with many irregular island structures on the inner surface is successfully machined. [ABSTRACT FROM AUTHOR]

Inconel-625 is a high-performance nickel-based superalloy which offers exceptional properties such as extensive resistance to corrosion, high strength-to-weight ratio, hardness, and impressive heat tolerance. Machining precise holes with required dimensional accuracy is challenging in Inconel-625 using conventional drilling processes. The investigation aims to improve the quality characteristics of hole machined on Inconel-625 by using the abrasive aqua jet drilling (AAJD) process. The influence of jet pressure ( J P ), table feed ( T F ), mass flow rate ( M FR ) and gap distance ( G D ) on the erosion rate ( E R ), surface roughness ( R a ), circularity error (CIerror) and striation zone ( S Z N ) are investigated. The weighted principal component analysis (WPCA)-based response surface methodology (WPC-RSM) is employed to analyze and optimize process parameters. The optimal parameter settings ( J P -300 MPa, G D -1.5 mm, T F -64 mm/min, M FR -0.55 kg/min) are observed to produce substantial improvement in response. Comparing initial and optimal conditions, the surface roughness ( R a ) is decreased by 10.15% from 3.25 μ m to 2.92 μ m. The CIerror and S Z N are also reduced by 38.02% and 12.74%, respectively. The erosion rate ( E R ) is improved by 8.79% with the optimal settings. J P is found to be the most influential parameter, followed by M FR . Scanning electron microscopy (SEM) pictures and 3D roughness plots are used in the surface topography analysis. [ABSTRACT FROM AUTHOR]

Functionality-oriented micro-structures, such as micro-dimples and grooves, are widely used in tribology and heat transfer. Jet electrochemical machining (JEM) is effective to fabricate micro-structures on metallic surfaces. However, in traditional JEM, the unrestricted electrolyte flowing can induce stray corrosion on workpiece, and thus, both surface quality and machining localization are reduced. In this paper, a novel electrolyte-confinement technique is proposed for JEM, a high-density liquid (perfluorotripropylamine, FTPA) is used to confine the electrolyte flowing region on workpiece when electrolyte exits nozzle, facilitating reduction in stray corrosion on workpiece and overcut of micro-structures. A multi-physics model including two-phase flow field and electric field is developed to analyze the electrolyte confined by FTPA, and both simulation and observation results show that the area of electrolyte flowing on the workpiece is confined well by FTPA, and the current density distribution becomes concentrated, which enhances the machining localization. Compared to traditional JEM, the etch factor of micro-dimple is improved by 2.5 times and there is no stray corrosion. The material removal rate is increased due to the concentration of current distribution on the workpiece surface. Furthermore, profile evolution of micro-dimples revealed that with feed depth increased, FTPA could flow into the micro-dimple to protect the sidewall from continuous dissolution, thus forming vertical sidewall. Additionally, electrolyte flowing region is still confined during the scanning motion of nozzle, and the etch factor increases from 0.41 to 8.8 compared to traditional JEM. Moreover, increasing inter-electrode gap could reduce electrolyte flowing region on workpiece, further enhancing machining localization. [ABSTRACT FROM AUTHOR]

Drilling precise micro-holes in glass material has brought a new challenge, primarily due to its application in microfluidic devices. It is required to reduce machining time and simultaneously achieve repeatability of the process. The machined hole should have minimum overcut to get desired hole diameter. Maximum hole circularity and minimum heat-affected zone are the essential hole characteristics to achieve controlled machining. The multi-criteria decision-making (MCDM) method is quite effective in selection of best possible combination of outputs from several alternative solutions. The experimental data from the previously published paper is used in the current study. As input parameters, the experiment data include voltage, tool feed rate, and machining time. The radial overcut (ROC), circularity of the machined hole and heat-affected zone (HAZ) were calculated as output responses. The experiments were conducted using copper and nickel-coated copper tools in previous study and response data were used in current work. The present study uses the methods which include hybrid grey relational analysis (GRA), technique for order performance by similarity to ideal solution (TOPSIS), and VIšekriterijumsko KOmpromisno Rangiranje (VIKOR) methods for the selection of the best combination of process parameters in drilling to obtain the optimal geometric characteristic of a hole, i.e. optimal values of ROC, circularity and HAZ, in glass using electrochemical discharge machining (ECDM). In this study, weight calculation for MCDM was proposed using entropy and analytic hierarchy process (AHP) methods and combined to get final weights using the fuzzy logic tool, which determines the importance of AHP and entropy weights using the expert opinion. The final weights were used to calculate the ranks from each MCDM method and determine optimal process parameter selection in ECDM hole drilling with copper and nickel-coated copper tools. The fuzzy logic method determined that the weight contribution from AHP is 0.586 in the present study. Genetic algorithm-based multi-objective optimization was conducted, and a non-dominated Pareto front was generated. The Spearman correlation method was used to determine the relationship between different MCDM methods. The current study will be helpful in selecting the best combination of process parameters in drilling holes during ECDM machining using MCDM methods. [ABSTRACT FROM AUTHOR]

The passivation characteristics of titanium alloys in electrolytes are often the main reason that impede the electrochemical reaction process. Hence, maintaining uniform electrochemical dissolution is a prerequisite for stable electrochemical machining (ECM) of titanium alloys. In this study, a novel cathode structure with built-in insulator is proposed, whichimproves machining stability of titanium alloys in ECM. Flow dynamics simulation results show that the cathodes with built-in insulator 1 or insulator 3 demonstrate more uniform flow effect. ECM experiments reveal that the optimized cathode can reduce the time of current from transition section to balance section, presenting a optimal transition time of 180 s. Compared with the original cathode, the sample surface machined using the optimized cathode is smooth without defects. Additionally, the optimal width of the non-processing stray corrosion area decreases from 603.47 μm to 214.54 μm, and 1010.47 μm to 349.25 μm. The optimal machining taper angle is 9.85°. [ABSTRACT FROM AUTHOR]

The current study explores the effectiveness of the ECM process when machining newly developed high entropy alloy (HEA)-reinforced magnesium composites. To evaluate the machinability, the study focuses on two key output constraints: surface roughness (Ra) and material removal rate (MRR). Experimental trials involve adjusting variables such as feed rate (FR), current, Electrolyte concentration (EC), & voltage in which experiment design is done through Taguchi method. Results highlights voltage as the most important input parameter governing Ra, followed by current. Similarly, voltage emerges as the primary influencer for MRR, with current being the second most influential. Furthermore, artificial neural networks (ANN) yielded predictions closely aligns with the experimental data. The optimal parameter set identified through CRITIC-WASPAS method included 5 Wt.% HEA, 15 V Voltage, 2 Amps current, 0.3 mm/min feed, and 25 g/lit electrolyte concentrations, resulting in a surface finish of 3.47 µm and a production rate of 0.039 mg/min. [ABSTRACT FROM AUTHOR]

This study investigated the impact of varying atomization amounts on composite machining involving both atomized electrical discharge ablation machining and electrochemical machining (EDAM-ECM). Additionally, this study examined the effects of different atomization amounts on the material removal rate, relative electrode wear rate, processing waveforms, surface roughness, surface morphology and elements, and the EDAM-to-ECM ratio. Moreover, a theoretical model for describing the material removal process in composite processing was developed. Furthermore, the effect of the ECM ratio on the processing results was quantitatively analyzed through the integration of statistical circuits with a formula for calculating recast layer thickness. The model was used to predict and select the optimal atomization amounts required to achieve recast layer removal during processing. The results revealed that at an atomization amount of 200 mL/min, 16.7% of the total material removal was attributable to ECM, indicating the successful removal of the recast layer. At this atomization amount, the fabricated sample maintained a machining precision of 0.02 mm. [ABSTRACT FROM AUTHOR]

High efficiency, high quality and green machining of single crystal silicon carbide (SiC) is an important issue in the third-generation semiconductor industry. In this paper, a novel machining method for single crystal SiC based on tribo-oxidation is proposed. The formula and preparation process of polysaccharide bonded soft abrasive tool were designed. Dry machining of C-face of 4H–SiC substrate was carried out with the prepared environmentally friendly abrasive tool sample. The material removal mechanism of the proposed machining method was preliminarily analyzed, and the material removal rate, surface roughness and subsurface residual stress were studied. The experimental results show that the maximum material removal rate of 4H–SiC can reach 1.03 μm/min with a corresponding average surface roughness of S a 0.816 nm. The machined surface has no brittle flaw, and subsurface residual compressive stress exists with a maximum value of 58.9 MPa. The material removal mainly attributed to the active oxidation of SiC surface induced by the friction between alumina abrasives and SiC substrate. The proposed machining method has potential application value in thinning of SiC wafers. [ABSTRACT FROM AUTHOR]

AbstractUsing closed integral components (CICs) not only simplifies the structure and reduces the weight of aeroengine components but also reduces the number of parts and improves overall engine performance. However, there are currently few publicly available reports on the electrochemical machining (ECM) of CIC blades. The key factor influencing the stability of ECM is the flow-field, which is difficult to design for a CIC because its two sides are closed, thereby limiting the direction of electrolyte flow into the processing area. To achieve the ECM of CICs, flow modes involving either lateral or composite liquid supply (LLS or CLS) are proposed, followed by flow-field and cathode-deformation simulation analyses. The simulation results show that the CLS flow-field is more reasonably designed and its electrolyte distribution is more uniform. The maximum cathode deformation under CLS flow-field is only ca. 15 µm. The experiments were conducted to improve the efficiency of CIC ECM and compare the LLS and CLS flow-fields. During processing, the feed rate was increased from 0.2 min/mm to 0.45 min/mm, and the surface roughness (Ra) decreased from ca. 1.29 µm to ca. 0.37 µm. The experiments show that the CLS flow-field offers higher processing efficiency and better surface quality. [ABSTRACT FROM AUTHOR]

High-precision surface of 201 stainless steel obtained by electrochemical micro-machining without or with magnetic field-assisted was studied by combining experiments and simulations. The results demonstrated that the surface roughness of the samples was reduced to 0.40 μm after 18 min electrochemical micro-machining. Besides, the introduction of the magnetic field further improved the surface accuracy and reduced it to 0.20 μm. At the same machining time, the magnetic field-assisted electrochemical micro-machining provided lower surface roughness, which indicated that the magnetic field had a favorable impact on the improvement of machining efficiency. Additionally, the distribution characteristics of magnetic induction lines in the machining gap were also discussed. When the magnetic induction lines were approximately parallel to the anode surface and perpendicular to the electric field, the processing efficiency was further improved. The simulation results showed that the current density on the anode surface and the mass transfer rate of the electrolyte were enhanced by the existence of the magnetic field, which accelerated the electrochemical reaction behavior. The external permanent magnet contributed magnetohydrodynamic force during electrochemical micro-machining promoting the occurrence of magnetohydrodynamic convection. Consequently, the charge and the mass transfer in electrolyte was expedited, indicating the improvement of processing efficiency. [ABSTRACT FROM AUTHOR]

Traditional blade electrochemical machining (ECM) adopts electrolyte unidirectional flow (EUF), resulting in serious accumulation of insoluble byproducts, gas, and Joule heat along the flow path. Here, an electrolyte intermittent commutation flow (EICF) was reported. Blade formed with EICF model was simulated, by comparison with EUF. Exploratory experiments were carried out, and how the time ratio of forward electrolyte flow time (tF) and reverse electrolyte flow time (tR) affects the blade ECM performance was investigated. The manufacturing accuracy and surface roughness depend on tF:tR, and they first improve and then deteriorate, reaching its optimal value at tF:tR = 1:3. Finally, the surface morphology is less affected by the tF:tR, the dissolution morphology exhibits that grain boundary is preferentially susceptible to electrochemical attack, compared with grain. The reason for this corrosion mechanism is that Ti and Nb are more easily enriched at the grain boundaries, while Cr, Fe and Ni are depleted. [ABSTRACT FROM AUTHOR]

Visual examination of the surface topography, in conjunction with the other sensors, may confirm the existence of chatter. Online chatter detection during real machining operations is possible with the use of sensors, and the presence of noise in their output and restricted bandwidth are the major drawbacks of these sensors. Productivity drops and manufacturing costs go up when there is a lot of chatter in the machining process. In the present paper, an integrated spindle tool system is modeled using finite element method with Timoshenko beam theory including rotational and shear deformation effects. To maximize the average stable depth of cut in an end milling process while simultaneously minimizing the chatter vibration levels, real time and offline strategies have been investigated. Machining experiments performed on Al6061-alloy specimens provide an empirical confirmation of the stability boundaries. The surface topography methods such as scanning electron microscope (SEM) and optical microscope images along with vibration levels are considered, to identify chatter marks under various machining conditions, which helps to assure cutting process stability. Stability lobe diagrams are plotted with these derived conditions and observed at an incremental level in the axial depths of the cut. The methodology shown in this paper improves the machining stability of the end milling with the reduction in the tool tip vibrations. [ABSTRACT FROM AUTHOR]

Tool condition monitoring is an important basis to ensure workpiece quality and machining efficiency. It is also a key factor in improving machining efficiency, ensuring machining accuracy. Therefore, a new method for predicting tool wear based on DenseNet-ResNet-GRU is proposed. Firstly, statistical theory and an improved wavelet threshold denoising method are used to improve the signal quality. In addition, the asymptotic semi-soft threshold function is applied to reduce the noise of the cutting force signal. Secondly, DenseNet, ResNet, and GRU (gate recurrent unit) deep learning networks are integrated to create a new tool wear prediction model to realize the nonlinear mapping relationship between the tool wear amount and the cutting force characteristic. Finally, the tool wear prediction model is verified by high-strength steel experiment. The experimental results verify the accuracy and reliability of the method, which has a better training effect and higher prediction accuracy compared with the CNN-GRU model. [ABSTRACT FROM AUTHOR]

In this study, metal matrix composite (MMC) materials were made with an aluminum matrix (AA7075 alloy) and reinforcement silicon carbide (SiC) elements using molten metal stir and indirect squeeze casting. SiC was used as a reinforcing element in the making of MMC material in different amounts (10%, 14%, and 18%) by mass. Electro Discharge Machining (EDM), cut depth (0.5 mm), three different pulse-on times, three different discharge current values, and a fixed pulse-off time (20 s) were used to machine MMC materials. The effects of machining parameters on machining time, average surface roughness, hole diameter, and material wear difference after machining were studied. As a result of the study, the composite material with 75 μ s pulse-on time, 6A current value, and 10% reinforcement element had the lowest machining time, the largest hole diameter, and the smoothest average surface. These machining parameters and materials also had the shortest machining time (5 min). Based on the signal-to-noise ratios, the best parameters for average surface roughness, hole diameter, Processing time, and material wear amount (MMC, discharge current value, and impact time) were found to be L 2 L 1 L 1 , L 3 L 1 L 1 , L 1 L 3 L 3 , and L 1 L 1 L 2 , respectively. Based on the ANOVA results, the R 2 values for the average surface roughness, hole diameter, machining time, and material wear loss value were 99.3%, 98.7%, 77.8%, and 97.3%, respectively. [ABSTRACT FROM AUTHOR]

Nitinol alloy is widely utilized across various industries due to its special properties. In this paper, the compound effects of two kinds of energy fields on material removal rate (MRR), hole wall quality, machining accuracy, and recast layer in ultrasonic combined magnetic field assisted EDM (UV-MFEDM were studied and analyzed. In addition, the influence of magnetic field intensity on the efficiency and accuracy of micro-hole machining is analyzed systematically. The results show that the surface quality of the micropore is significantly improved, the MRR is increased by 31.6%, the taper of the micropore is reduced by nearly 30%, the overcut diameter is reduced by nearly 23%, the recast layer is more uniform and the thickness of the recast layer is reduced by nearly half. Appropriate magnetic field intensity proves beneficial for improving micro-hole machining efficiency while reducing both taper angle and diameter overcut of micro-holes. [ABSTRACT FROM AUTHOR]

This article investigates the effects of mixing different alkaline electrolytes on the geometrical features created by the ECDM. Sodium hydroxide (NaOH) and potassium hydroxide (KOH) were mixed in varying volumetric proportions. Effect of critical process parameters on the depth and width of the microchannels and the associated tool wear was investigated. Pure NaOH electrolyte has resulted in the highest depth compared to the pure KOH electrolyte. Process mechanism behind the role of mixed electrolytes on the opening sizes and depths of microchannels is explained. Higher material removal by the NaOH electrolyte was due to the larger number of sodium (Na+) ions in the electrolyte, resulting in more aggressive electrochemical discharge; however, it also resulted in severe tool wear. Mixed electrolytes with a KOH yielded lower width and low tool wear. Increasing the volumetric proportion of KOH in the mixed electrolyte gradually decreased the machining depth, width, and tool wear. [ABSTRACT FROM AUTHOR]

AbstractThe development of wire electrochemical spark machining setup is always challenging in the form of industrial viable for machining advanced engineering materials such as polymer nanocomposites, quartz, glass, ceramics, etc. Because of some drawbacks associated with it, like irregularity in kerf width, poor surface finish, no spark formed at high wire velocity, wire breaking at high voltage, etc. In the present work, a newly developed hybrid machining process that is reversible motion-wire electrochemical spark machining (RM-WECSM) has been developed for curve profile cutting, especially on non-conducting workpieces such as aluminum oxide epoxy nanocomposite of 3.5 mm thickness. The effect of NaOH concentration, applied voltage, reversible wire velocity, pulse on-and-off time, on material removal rate and average surface roughness have been studied using a one-parameter-at-a-time approach. Sparking occurred from the electrolyte surface to 10 mm above the electrolyte surface to cut the workpiece. The spark length is equal to the workpiece thickness. A continuous, stable spark has been formed at a high reversible wire velocity (19.8 m/min). Simultaneously, self-electrolyte flow has been generated, due to which melted materials have been washed out of the cut-surface and provided the smooth (1.987 µm) cut-surface of the workpiece. The maximum MRR is found as 1.63 mg/min. Thermal cracks, heat-affected zones and recast layers were not found on the curve cut-surface, and it was analyzed by a field emission scanning electron microscope. [ABSTRACT FROM AUTHOR]

AbstractThis article introduces a novel model reconstruction method for machining turbine blades damaged in service and repaired via additive manufacturing (AM). Addressing the lack of a model for damaged parts crucial for precise adaptive machining, the method involves model registration and construction. Initially, the AM-repaired blade is aligned with a theoretical CAD model through rough registration using Principal Component Analysis (PCA), followed by precise alignment within the blade profile’s tolerance zone. The model construction employs the minimum curve energy principle to ensure seamless integration with undamaged areas and adherence to profile tolerance constraints. The interfacial profile curve between the undamaged and AM-repaired areas is used as the original curve to construct the curves in the AM-repaired area. The reconstructed curves are modified with a double constraint of being smooth and minimum occupation of the theoretical model tolerance zone. The efficacy of this method is validated through a case study. The repaired blade showed deviations from −0.101 mm to 0.115 mm, within profile tolerances, and a surface smoothness difference of less than 6.41 μm between the damaged and undamaged sections. This method significantly improves the precision and efficiency of turbine blade repair, offering substantial benefits for the turbomachinery manufacturing industry. [ABSTRACT FROM AUTHOR]

In this review, recent advances regarding the integration of machine learning into electrochemical analysis are overviewed, focusing on the strategies to increase the analytical context of electrochemical data for enhanced machine learning applications. While information-rich electrochemical data offer great potential for machine learning applications, limitations arise when sensors struggle to identify or quantitatively detect target substances in a complex matrix of non-target substances. Advanced machine learning techniques are crucial, but equally important is the development of methods to ensure that electrochemical systems can generate data with reasonable variations across different targets or the different concentrations of a single target. We discuss five strategies developed for building such electrochemical systems, employed in the steps of preparing sensing electrodes, recording signals, and analyzing data. In addition, we explore approaches for acquiring and augmenting the datasets used to train and validate machine learning models. Through these insights, we aim to inspire researchers to fully leverage the potential of machine learning in electroanalytical science. [ABSTRACT FROM AUTHOR]

High‐rate dissolution process of Ti–48Al–2Cr–2Nb alloy in electrochemical machining exhibits strong nonlinear dynamic characteristics, but the quantitative relationship between these nonlinear characteristics and surface topography, as well as the electro‐dissolution mechanism, is unknown. Therefore, the fractal and recursive features of dissolution behavior and quantitative characterization of the dissolved surface topography were investigated. Additionally, an electro‐dissolution mechanism model in electrochemical machining process was presented. Applying a higher potential of 11 V can enhance the stability of the electrochemical system, resulting in a smoother and uniform surface. The saturation correlation dimension, surface roughness, and integral area of lacunarity initially decrease before increasing with higher electrolytic pressure, while laminarity and determinism show an initial increase followed by a decrease. These five characteristic parameters reach their optimal values at an electrolyte pressure of 0.4 MPa, indicating that achieving a stable and deterministic electrochemical system is crucial for obtaining a uniform smooth surface. These nonlinear dynamic characteristic parameters can be considered as in‐situ monitoring parameters for surface quality in ECM. The anodic dissolution process comprises three stages: initial passive film dissolution and breakdown, rapid dissolving with surface coarsening, and stable dissolving with polishing. [ABSTRACT FROM AUTHOR]

Extrusion tapping (ET) poses a technical difficulty when processing internal threads with large depth, small diameter, and high-precision blind hole. In addition, conventional ET (CET) of Ti-6Al-4V small internal blind-hole threads with large length-to-diameter ratio is challenging given its small elastic modulus, large deformation resistance and easy cracking in cold forming. To this end, a novel longitudinal–torsional ultrasonic vibration–extrusion tapping (LT-UVET) is proposed to address the technical problem of these threads. On the basis of ultrasonic longitudinal–torsional vibration characteristics, the motion trajectory equations of LT-UVET were deduced. The motion model of LT-UVET was established, and the intermittent extrusion law and force state between the tap extrusion edge and the processed material were explored and studied. Furthermore, tapping experiments were conducted to compare the differences in torque, thread quality, microhardness, and tap wear obtained by CET and LT-UVET. The influence of different tapping speeds on the thread was studied through singlefactor experiment. According to experimental findings, the maximum tapping torque was reduced by 9 %–26 % compared with CET. Moreover, the surface integrity and the profile of the thread were improved. The overall microhardness of threads increased by 3 %–17 %. The wear area of the tap lobes in LT-UVET is reduced by 65 % compared with that of CET. Therefore, the introduction of longitudinal–torsional ultrasonic vibration into the extrusion zone enhances the machinability of Ti-6Al-4V, which in turn improves the quality of extruded threads and increases the efficiency of thread machining. [ABSTRACT FROM AUTHOR]

The lubricating medium of the aerostatic spindle is gas, with relatively low rigidity, which is easy to cause rotor offset and additional vibration under the action of external load, thus affecting the processing accuracy of the spindle. To solve the problem of unbalanced vibration of the spindle, a new type of controllable radial aerostatic bearing is designed by combining piezoelectric ceramics, which use the inverse piezoelectric effect of piezoelectric ceramics to squeeze the air film to produce corresponding control force, and the radial unbalanced vibration of the spindle is suppressed. A bearing–rotor–piezoelectric ceramic coupling model was established, and the control method of feedforward combined with feedback was used to reduce the hysteresis characteristics of piezoelectric ceramics. On this basis, the sliding mode controller of the entire system, and through research, it is found that the sliding mode controller based on the extended observer has the best vibration suppression effect compared with other sliding mode controllers in the article; this research results can improve the rotation accuracy of the spindle system and the machining accuracy of ultra-precision machine tools. [ABSTRACT FROM AUTHOR]

Manufacturing internal splines with complex structures in high-hardness materials poses challenges in conventional machining processes. This paper introduced a new electrochemical machining (ECM) method using an assembled tool cathode with a cathode working teeth sheet with circumferential vibration for efficient and stable shaping of involute internal splines of intricate high-hardness components. A detailed design of the assembled tool cathode is presented, accompanied by flow field simulations analysing electrolyte distribution during circumferential vibration. A specific experimental system, fixture, and a used electrolyte filter module were constructed for spline ECM experiments. The results show that with the cathode feed rate of 2.7 mm/min, and the circumferential vibration frequency of 80 Hz, the involute internal spline profiles were successfully shaped with higher precision and efficiency with less appropriate allowance. • A novel ECM approach featuring an assembled tool cathode, equipped with teeth that vibrate circumferentially, is introduced for enhanced machining. • Circumferential vibration of the cathode is shown to improve electrolyte distribution in the area where tooth roots are machined, facilitating better machining outcomes. • An experimental ECM system for spline machining, complete with a dedicated fixture and a module for filtering used electrolyte, has been developed. • Utilizing a cathode feed rate of 2.7 mm/min and a vibration frequency of 80 Hz, precise involute internal spline profiles are achieved with minimized excess material. [ABSTRACT FROM AUTHOR]

GH4169 alloy/Inconel 718 is extensively utilized in aerospace manufacturing due to its excellent high temperature mechanical properties. Micro-structuring on the workpiece surface can enhance its properties further. Through-mask electrochemical micromachining (TMEMM) is a promising and potential processing method for nickel-based superalloys. It can effectively solve the problem that traditional processing methods are difficult to achieve large-scale, high-precision and efficiency processing of surface micro-structure. This study explores the feasibility of electrochemical machining (ECM) for GH4169 using roll-print mask electrochemical machining with a linear cathode. Electrochemical dissolution characteristics of GH4169 alloy were analyzed in various electrolyte solutions and concentrations. Key parameters including cathode sizes, applied voltage and corrosion time were studied in the roll-print mask electrochemical machining. A qualitative model for micro-pit formation on GH4169 was established. Optimal parameters were determined through experiments: 300 μm mask hole and cathode size, 10 wt% NaNO3 electrolyte, 12 V voltage, 6 s corrosion time. The results demonstrate that the micro-pits with a diameter of 402.3 μm, depth of 92.8 μm and etch factor (EF) of 1.81 show an excellent profile and localization. [ABSTRACT FROM AUTHOR]

During the machining process, problems such as tool wear, high temperature, force distribution, and surface quality deterioration must be fully understood. Control of these problems with experimental studies and numerical analyses is important in ensuring dimensional accuracy and surface integrity of the cutting tool, workpiece, and also the finished product. The aim of this study is to investigate the effects of machining parameters on chip morphology, residual stresses and tool wear in turning operations of ASTM-F75 CoCrMo alloy experimentally and by finite element method (FEM) simulation. The study was carried out at three different feed rates (0.1, 0.2, 0.3 mm/rev) and at a constant cutting speed of 80 m/min both experimentally on a CNC turning machine and with FEM simulation. From the obtained results, the formation of cracks and adhesions on the surfaces of the chip were observed due to the increase of the feed rate. According to the orthogonal cutting model, chip height ratio (Gs) and tooth pitch (Pc) values of saw-tooth chips supported each other with measurements taken from both FEM images and experimental images. With the increase of the forward speed, the Gs ratio decreased, while the Pc increased. In addition, microscopic images obtained from the cutting tool also showed that the rate of crater wear gradually increased with increasing feed rate. As a result, it is seen that machining parameters have a significant effect on cutting tool and chip morphology in CoCrMo ASTM-F75 alloy turning. [ABSTRACT FROM AUTHOR]

Machining of silica glass is a challenging task due to its physical properties like brittleness, electrically insulated, etc. Although with the use of electrochemical discharge, it is possible to make holes and channels in silica glass, but the generation of spark discharge and removal of materials is a complex phenomenon in the electrochemical discharge process. Several research works were carried out previously to control the spark discharge as well as machining accuracy using rotational tool, the addition of ultrasonic vibration, including a magnetic field, and the use of different electrolytes, etc. A novel tool feeding technique i.e. using a horizontal tool and vertically upward tool feeding technique was used during milling on glass. The effects of voltage, the tool feed rate (TFR) and the concentration of electrolyte on the material removal rate and machining quality were studied in this work. The machined channel was examined under an optical measuring microscope as well as scanning electron microscope. The machining surface was also observed using a coherence correlation interferometry image to analyze in-depth surface topography of machined channels. Material removal rate and Ra value of the bottom layer were measured. The material removal rate of 6.097 µg/min was noticed at 25 wt% of electrolyte concentration, 40 µm/s of TFR and 45 V of applied voltage. The bottom layer's surface roughness (Ra) was found as low as 0.222 µm (Ra) at parametric conditions of 40 V, 40 µm/s TFR, and 15 wt% electrolyte concentration by employing the developed novel tool feeding technique. [ABSTRACT FROM AUTHOR]

The electrochemical discharge machining (ECDM) is an advanced and promising technology for fabricating micro structures. This method is effectively applicable for non-conductive hard and brittle materials micromachining, such as glass and ceramics. However, the ceramics high melting point and intense heat exchange effects during microchannel fabrication lead to the easy dissipation of thermal energy and the difficulty in processing. To address this issue and expanded the ECDM processing range. This paper dedicated to the investigation of the material removal mechanism and process characteristics for the alumina ceramic surfaces microchannels preparation. Firstly, this study explained the difference of the ECDM critical applied voltage and gas film generation mechanism by analyzing the volt-ampere characteristic curve of 20 wt% NaOH electrolyte with a tool immersed depth of 2 mm and 10 mm respectively. Then, a thermal removal finite element model (FEM) for ECDM was developed. The heat cumulative and intermittent cooling effects applied on the alumina ceramic surface dominated the materiel removal. Additionally, it can be found that the microchannel machining accuracy and bottom surface quality depended on the Gaussian heat source characteristics, gas film formation mechanism, heat accumulation effect, and temperatures spatial and temporal distribution. And a series of single factor experiments for evaluating the parametric studies such as the effect of discharge frequency, applied voltage, duty ratio and tool feed rate on the fabricated microchannel performance are executed. Finally, the complex three-dimensional structures of cross microchannel grid and zigzag microchannel array with variable depth were successfully fabricated on aluminum oxide ceramic surface. Notably, the results highlighted and enriched the ECDM stability, consistency and applicability for alumina ceramic surface microchannel fabrication. [ABSTRACT FROM AUTHOR]

Higher accuracy and meticulousness are highly demandable in modern industrial field during micro-machining performances by electrochemical discharge machining (ECDM) process. The paper deals with the experimental fuzzy logic control (FLC) analysis as well as artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS) analysis during micro-channel fabrication on silica glass. A comparative analysis of FLC, ANN as well as ANFIS has been performed and experimental error prediction has been propounded to estimate minimum error possibilities such as mean absolute error (MAE), root mean square error (RMSE) and regression value (R). Computational time training dataset, minimum sample size and prediction time are also illustrated in this paper. In this paper, ANN, FLC and ANFIS models are analyzed for tool wear rate (TWR) and heat-affected zone (HAZ). 3D Rule Viewer and regression analysis as well as validation of test results and characteristics graph between performances with number of epochs of ANN model also are included in this paper for TWR and HAZ. Influence of process parameters like voltage, duty ratio, pulse frequency and electrolyte concentration on Surface Viewer of TWR and HAZ is also illustrated. It is found that ANFIS has great effectiveness of prediction of error during micro-ECDM process. [ABSTRACT FROM AUTHOR]

The grain size effect is an important factor in determining the material removal behavior of polycrystalline silicon (p-Si). In the present study, to improve the understanding of nanoscale machining of p-Si, we performed molecular dynamics simulation of nanometric cutting on a p-Si workpiece and discussed the grain size effect on material removal behavior and subsurface damage formation. The simulation results indicate that when cutting on the polycrystal workpiece, the material removal process becomes unstable compared with single crystals. Higher removal efficiency, less elastic recovery and higher frictional coefficient are observed as the average grain size decreases. In the subsurface workpiece, when the grain size decreases, slip along grain boundaries merges as a nonnegligible process of the plastic deformation and suppresses the elastic deformation ahead of the cutting tool. It is also revealed that when cutting on a polycrystal workpiece with smaller grains, the average stress decreases while the workpiece temperature increases due to the impediment of heat transfer by grain boundaries. These results could provide a fundamental understanding in the material deformation mechanism of p-Si during nanoscale machining. [ABSTRACT FROM AUTHOR]

Bulk metallic glasses (BMGs) are growing in popularity prominently due to their potential in micro-electromechanical systems (MEMSs) and aerospace applications. BMGs have unique mechanical properties, i.e., high strength, hardness, modulus of elasticity, and wear resistance, due to their disordered atomic structure. Due to their unique mechanical properties and amorphous structures, machining of BMGs remains a challenge. This paper aims to carry out a detailed literature review on various aspects of the machining of bulk metallic glasses using both conventional and non-conventional processes, including experimental approaches, modeling, statistical findings, challenges, and guidelines for machining this difficult-to-machine material. Conventional machining processes were found to be challenging for machining bulk metallic glasses due to their high hardness, brittleness, and tendency to convert their amorphous structure into a crystalline structure, especially at the machined surface and sub-surface. Although their high electrical conductivity makes them suitable for machining by non-conventional processes, they impose new challenges such as heat-affected zones and crystallization. Therefore, the successful machining of BMGs requires more in-depth analysis of cutting forces, tool wear, burr formation, surface finish, recast layers or heat-affected zones, crystallization, and mechanical property changes among different varieties of BMGs. This review paper provides guidelines emerging from in-depth analysis of previous studies, as well as offering directions for future research in the machining of BMGs. [ABSTRACT FROM AUTHOR]

Surface defect detection is a critical task in the manufacturing industry to ensure product quality and machining efficiency. Image-based precise defect detection faces significant challenges due to defects lacking fixed shapes and the detection being heavily influenced by lighting conditions. Addressing the efficiency demands of defect detection algorithms, often deployed on embedded devices, and the highly imbalanced pixel ratio between foreground and background images, this paper introduces a multi-scale fusion staged U-shaped convolutional neural network (DEU-Net). The network provides segmentation results for defect anomalies while indicating the probability of defect presence. It enables the model to train with fewer parameters, a crucial requirement for practical applications. The proposed model achieves an MIoU of 66.94 and an F1 score of 74.89 with lower Params (36.675) and Flops (19.714). Comparative analysis with FCN, U-Net, Deeplab v3+, U-Net++, Attention U-Net, and Trans U-Net demonstrates the superiority of the proposed approach in surface defect detection. [ABSTRACT FROM AUTHOR]

The main purpose of this study was to develop observation techniques and processing technology for the electrochemical discharge machining (ECDM) of sapphire wafers. To measure the effect of gas-film thickness, discharge-spark conditions, and droplet sliding frequency on machining quality and efficiency in ECDM, this research utilized high-speed cameras to observe the gas film thickness and formation of the gas film during ECDM. Additionally, this study observed the machining-gap phenomena during ECDM. The formation mechanism and machining characteristics of the gas film were understood through experiments. The machining parameters included the liquid level, working voltage, rotation speed, and duty factor. This study analyzed and discussed the effect of each machining parameter on the gas-film thickness, current, electrode consumption, and droplet sliding frequency. Moreover, this study aimed to obtain optimized machining parameters to overcome the difficulty of machining sapphire. The experimental results indicated that utilizing a high-speed camera to capture the phenomena between electrodes during electrochemical discharge could effectively observe the gas-film thickness and the coverage of the gas film. A higher bubble coalescence rate enhanced the machining capability and reduced the lateral discharge. Therefore, this study could obtain better machining-hole depths through observation and analysis to improve gas-film stability and machining capability. This study demonstrated that a liquid level of 700 µm, a working voltage of 48 V, a duty factor of 50%, and a tool electrode rotational speed of 200 rpm could achieve a hole depth of 86.7 µm and a hole diameter of 129.5 µm. [ABSTRACT FROM AUTHOR]

Owing to the incapability of the existing techniques, Electrochemical Spark Machining (ECSM) is transpiring to micro machine the glass for potential applications in micro domain. However, in ECSM, the bubble accumulation and poor flushing lead to the generation of a non-uniform gas film, resulting in the deterioration of Hole Circularity (HC) and Surface Roughness (SR). Therefore, present communication is an attempt toward the concept of Rotary-Magnet assisted ECSM (RM-ECSM) to produce the micro holes in the borosilicate glass with better quality characteristics (higher HC and lower SR), which are required for better performance of glass vias in RF-MEMS. The evolutionary algorithm and Machine Learning (ML) have been adopted for optimization. From optimization, the values of optimal input parameters were obtained as follows: Applied voltage = 43.46 V; Electrolyte-temperature = 45.93 ֯ C; Pulse on time = 3.28 ms; Magnetic rotation = 551 rpm with corresponding values of HC and SR as 79.28% and 3 um respectively. Finally, these outcomes were validated by Levenberg-Marquardt algorithm (ML). [ABSTRACT FROM AUTHOR]

Electrochemical discharge machining (ECDM) micro-milling exhibits enormous machining potential in manufacturing metal microstructures. In this paper, a novel sinking ECDM micro-milling using glycol-based electrolyte is proposed for the high-quality fabrication of metal micro-channel structures. Firstly, a novel combined process is developed for the simple and efficient preparation of micro-electrode. With the proposed method, a micro-electrode with 91.1 μm in diameter and 21.2:1 in aspect ratio is successfully machined in 47.2 minutes. Secondly, experimental research on ECDM micro-milling machining of micro-channels in glycol-based electrolyte is carried out using the fabricated micro-electrode. Experimental results show that the machined voltage significantly affects the machining quality of micro-channels. Wear analysis reveals that the bottom geometry of the micro-electrode exhibits equal wear along the axis direction with processing times increasing, and a constant length compensation strategy (1.52 μm/mm) is adopted. Finally, an S-shaped micro-channel without recast layers (Ra 0.093 μm) was successfully fabricated. [ABSTRACT FROM AUTHOR]

Electrochemical discharge machining (ECDM) is a micro-machining hybrid technique that utilizes electrical discharge and electrochemical machining principles. However, the issue of insufficient electrolyte in the hydrodynamic region hinders the continuation of the machining action. Although ultrasonic tool vibrations have been used to overcome this problem to some extent, the excessive mechanical energy produced by high-amplitude tool vibration may lead to surface crack formations. As a result, the present work employs two flushing improvement methods, namely the ultrasonic vibrations and magnetic filed assistances, in the ECDM process. A comparative study has been performed to identify the effect of the magnetic field on discharge quality. The material removal rate and depth of penetration were increased by 11% and 24%, respectively, and the observed reduction in hole overcut and taper angle was around 35% and 50%, respectively. Optical microscope images quantified improvement in dimensional accuracy and decreased HAZ area. [ABSTRACT FROM AUTHOR]

The electrochemical machining process involves electrical and chemical processes while removing materials from the workpiece. Electrochemical machining (ECM) lacks accurate models for predicting the shape and material removal rate during the ECM process. This limits the ability to optimise the process and predict the final product geometry, which is crucial for industrial applications. This research mainly focused on the modelling and simulation of material removal from the workpiece using COMSOL Multiphysics software. This research involves developing a mathematical model that describes ECM's electrical, chemical, and mechanical interactions. The model is based on electrochemistry, fluid dynamics, and solid mechanics principles and will be solved using numerical simulation techniques. Various workpiece materials considered in this investigation include Aluminium, Nickel, Stainless Steel, and Tungsten, whereas copper is electrode material. The effects of the various parameters, such as workpiece materials, the voltage applied during machining, and electrolyte conductivity on the material removal rate are being investigated. In addition, the shape of the machined workpiece is also predicted. The results of this research provide a deeper understanding of the underlying physics of the ECM process and lead to the development of more accurate models for predicting the shape and material removal rate during ECM. [ABSTRACT FROM AUTHOR]

With escalating demand for machinability, economical production, health, and environment-related aspects are pushing the present industrial units to drop the usage of harmful-cutting fluid in machining. However, the adaption of this approach for machining difficult-to-cut materials does not ensure favourable outcomes of the tool performance, surface qualities, etc., as friction and heat seriously disturb machining efficiency. This study is focused on near-dry machining employing recently developed hybrid nanofluids-based lubrication in the machining of AISI 52,100 steel. Hexagonal boron nitride (hBN) and silicon carbide (SiC) nanoparticles are added to the lubrication oil to enhance the performance of the Minimum Quantity Lubrication (MQL) system. Taguchi's method-based Grey relational analysis (GRA) is used for the concurrent optimisation of the tool flank wear and surface roughness. The best parametric setting for the multi-response is achieved as: a lubricant flow rate of 150 ml/h, depth of cut of 0.2 mm, and nanofluid with 0.8 wt % of hBN and 0.2 wt % of SiC nanoparticles. The confirmation experimentation concluded that the multi-response factor is enhanced by 2.48% at the optimum setting with the mean values of TFW and SR as 84 and 0.36 µm, respectively. [ABSTRACT FROM AUTHOR]