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Micromachines 2019, 10(1), 28; https://doi.org/10.3390/mi10010028

Fabrication of Taper Free Micro-Holes Utilizing a Combined Rotating Helical Electrode and Short Voltage Pulse by ECM

Associated Engineering Research Center of Mechanics and Mechatronic Equipment, Shandong University, Weihai 264209, China
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Received: 22 November 2018 / Revised: 27 December 2018 / Accepted: 28 December 2018 / Published: 3 January 2019
(This article belongs to the Section D:Materials and Processing)
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Abstract

Fabrication of the injection nozzle micro-hole on the aero engine is a difficult problem in today’s manufacturing industry. In addition to the size requirements, the nozzle micro-hole also requires no burr, no taper and no heat-affected zone. To solve the above problem, an ultra-short voltage pulse and a high-speed rotating helical electrode were used in electrochemical drilling (ECD) process. Firstly, a theoretical model of ECD with ultra-short voltage pulse was established to investigate the effects of many predominant parameters on machining accuracy, and the effect of rotating helical electrode on the gap flow field was analyzed. Secondly, sets of experiments were carried out to investigate the effects of many key parameters on machining accuracy and efficiency. Finally, the optimized parameters were applied to machine micro holes on 500 μm thickness of GH4169 plate, and micro-holes with the diameter of 186 μm with no taper were machined at the feed rate of 1.2 μm/s. It is proved that the proposed ECD process for fabricating micro-holes with no taper has a huge potential and broad application prospects. View Full-Text
Keywords: ultra-short pulse; helical electrode; theoretical model; electrochemical drilling (ECD); micro holes ultra-short pulse; helical electrode; theoretical model; electrochemical drilling (ECD); micro holes
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Liu, Y.; Li, M.; Niu, J.; Lu, S.; Jiang, Y. Fabrication of Taper Free Micro-Holes Utilizing a Combined Rotating Helical Electrode and Short Voltage Pulse by ECM. Micromachines 2019, 10, 28.

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