Papers by Author: C.Y. Yao

Abstract: In this study the prediction of the erosion profiles during ECM of the spiral hole was presented. By assumptions, the major points were simplified into one-dimensional problems. The theoretical and computational model was built to illustrate the profile movement as the time elapses. The analysis was based on the law of electrolysis and the software MATLAB was used. Verifications were done through experiments and the deviation was 7.5% between theoretical and experimental result. On the basis of the prediction of the erosion profile, the applied parameters could be estimated.

Abstract: Electrochemical machining (ECM) technology has the advantage of machining the workpiece with complex profile on the basis of electrolysis. In this study, turbulated holes with the rib’s shape of spiral and annular were processed by ECM by using the shaped cathodes. Experimental system was built which consists of electrolyte supply module, power supply unit and workpiece holding device. Machining experimentations were carried out on the built system. Analysis and discussions were done according to the experimental results. It indicated machining efficiency is high by using the shaped cathode. Machining error could be controlled within 10-20%.

Abstract: Diamond wire saw is the leading technology for use in cutting hard brittle material. Its smaller kerf and faster cutting time make it replacing the conventional slurry technology for those materials. Turned over the traditional router, this paper presents a novel approach that replaces the typical metallic core with a nonmetallic core, for manufacturing of ultraviolet curing resin fixed-abrasive diamond wire saw (DWS). The experiments show that the diamond wire saw made by this manufacturing method can obtain a good performance as well as taking many other advantages.

Abstract: The machining of materials on microscopic scales is considered to be great importance to a wide variety of fields. Electrochemical Micro-machining (EMM) appears to be promising to machine the micro-structures in future due to the material is dissolved at the unit of ion. This paper is focused on developing a micro electrochemical machining system in which the micro-structures such as micro-cylinder, multiple micro-electrodes, micro-holes and micro-slot were processed. The micro-electrodes were prepared in a precisely controlling the electrochemical etching process. Mathematical model controlling the diameters of electrodes was built up. Furthermore, the obtained micro-electrodes were selected as the cathode tool for micro holes drilling and micro-slot milling using pulse power in Micro-ECM.

Abstract: The interfacial bonding strength between ultraviolet-curing resin and diamond is a key factor affecting tool properties in manufacturing of ultraviolet-curing wire saw. Therefore, in this paper, the application of surface-modified diamond coated metal was studied in ultraviolet-curing wire saw aim at retention problem of diamond in bond. Effects of surface-modified diamond were evaluated according to model of tensile test. Furthermore, retention mechanism of diamond was analyzed according to bond theory. The experimental results prove that the machining properties and service life of ultraviolet-curing wire saw can be improved by surface modification of diamond.

Abstract: This paper provides a novel process that can readily make abrasive tools bonded ultraviolet-curing resin. Excellent characteristics of ultraviolet-curing resin make it possible for bonding abrasive tools. Moreover, more applications demonstrate that ultraviolet-curing abrasive tools possess excellent properties without the shortcomings that are encountered in the case of the conventional resin bonded abrasive tools. Furthermore, various factors influencing the qualities of ultraviolet-curing abrasive tools are discussed.

Abstract: This paper describes a method for experimental development of a novel fixed abrasive nano-grinding plate (FAG-plate) which is proposed for lapping some rigid brittle materials, such as quartz crystal and silicon. The FAG plate is developed with ultraviolet-cured resin by rapid prototyping technology. The analysis shows that such FAG-plate can keep its grinding ability constant and continuous and it can make the roughness of machined surface reach to nanometer level. Based on experimental comparisons with conventional free abrasive slurry lapping plates, the lapping process using FAG-plate has several distinct advantages. One is that the machining efficiency is significantly improved. The second is that it improves the surface roughness of machined work-pieces, although it decreases the flatness tolerance of materials. Furthermore, the fixed abrasive nano-grinding plate is made by the new bonding materials- ultraviolet curing resin and thus the fabrication of FAG-plate is convenient and economical.

Abstract: In recent work, a creative idea has been proposed by applying the rapid prototyping technology to develop a new diamond-coated blade based on ultraviolet-cured resin bond. The new technology features many advantages such as fast processing speed, low environmental pollution, and low energy consuming. This paper makes an investigation on the adherence and abrasion mechanisms of such diamond blades. The experimental plan is well designed for selection of an optimal prescription of the mixture to achieve good mechanical performance and a manufacturing process is proposed to produce ultraviolet-cured resin bonded diamond coated blades. Practical experiments are carried to test the blade performance and to compare with different tools in incising artificial crystal. Furthermore, this paper also observes how the tensile strength and elastic modulus of ultraviolet-cured resin affect the crevasse and quality of machined edge surfaces.