Research on ECM process of micro holes with internal features |
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| Affiliation: | 1. Beijing Key Lab. of Precision/Ultra-Precision Manufacturing Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. State Key Laboratory of Tribology, Tsinghua University, Beijing 100084, China;3. School of Instrumentation Science and Opto-Electronics Engineering, Beijing Information Science & Technology University, Beijing 100192, China;1. School of Materials Science and Engineering, Tianjin University, Tianjin 300350, China;2. Collaborative Innovation Center of Advanced Ship and Deep-Sea Exploration, Shanghai 200240, China;3. School of Aviation Engineering, Civil Aviation University of China, Tianjin 300300, China;4. Ansteel Mining Engineering Corporation, Anshan 114004, China;1. Department of Mechanical Engineering, KU Leuven, 3001, Heverlee, Belgium;2. Flanders Make, Belgium;1. Department of Production Engineering, Faculty of Mechanical Engineering, University of Technology and Life Sciences in Bydgoszcz, Poland;2. Department of Digital Technology, Faculty of Telecommunications and Electrical Engineering, University of Technology and Life Sciences in Bydgoszcz, Poland;1. Tokyo University of Agriculture and Technology, 2-24-16 Nakamachi, Koganei City, Tokyo 184-8588, Japan;2. Keisoku Engineering System Co.,Ltd., 1-9-5 Uchikanda, Chiyoda-ku, Tokyo 101-0047, Japan |
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| Abstract: | Micro holes with internal features are widely used as spray holes and cooling holes nowadays, which are usually required to be with high aspect ratio and shape accuracy, as well as good surface quality. An electrochemical machining (ECM) process is presented to machine these micro holes with diameter <200 μm. A quantitative relation between micro-hole diameter and machining parameters including voltage, duty ratio and feedrate is obtained through orthogonal experiments. According to the designed shape of internal features, change rules of machining parameters for varied diameters in different depth are obtained, and then micro holes with internal features are shaped precisely. Taking reverse tapered hole as an example, ECM experiments by varying parameters of voltage, duty ratio and feedrate (called varying voltage machining, varying duty ratio machining and varying feedrate machining, respectively) are carried out. Micro holes with inlet diameter of 178 μm and taper angle of 1.05° are shaped on a 1.0 mm-thick workpiece of 18CrNi8. The deviation of inlet is <3 μm and the taper-angle error is <0.1° in varying voltage machining. The corresponding dimensional accuracy of taper angle is improved by 51% than that of varying duty ratio machining under the same efficiency. The machining efficiency of varying voltage machining is increased by 36% compared to the efficiency in varying feedrate machining. In addition, the micro holes with complex features of funnel shape and bamboo shape are machined. |
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| Keywords: | ECM Internal features Micro reverse tapered hole High aspect ratio Varying voltage machining |
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