Electro-Chemical Micro Drilling by Micro-Spherical Electrode

Abstract:

Manufacture of micro holes in difficult-to-machine material is very difficult, electro-chemical machining (ECM) is one of the more appropriate approach. However, micro holes fabricated using ECM can have different diameters at the entrances and exits and such tapering effect is not localized. In this work, a new ECM method named electro-chemical micro drilling (ECMD) for machining high quality straight micro holes in difficult-to-machine material was introduced, and the micro-spherical electrode fabricated by a hybrid technique combining micro-ECM with one pulse electro discharge (OPED) was used in ECMD process. Micro-spherical electrode and ultra short pulses (tens of nanosecond scale) were used to locally dissolve the area with the effect of voltage, pulse width and pulse frequency on the localization distance being studied. High quality micro holes with a diameter of 42 µm in a 70 µm thick nickel foil were drilled using micro-spherical electrode with a sphere diameter of 30 µm.

• Periodical: Advanced Materials Research (Volume 1089)
• Pages: 324-330
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.1089.324
• Online since: January 2015
• Authors: Han Song Li*, Dong Meng, Guo Qian Wang, Yong Bin Zeng
• Keywords: Drilling, Electro-Chemical Machining, Micro Holes, Micro-Spherical Electrode

References

[1] V. Baghlani, P. Mehbudi, J. Akbari and M. Sohrabi. Ultrasonic Assisted Deep Drilling of Inconel 738LC Super-alloy. CIRP 17th Conf. on Electro Physical and Chemical Machining (Leuven, Belgium, 9-12 April. 2013).

DOI: 10.1016/j.procir.2013.03.096

[2] I. Muhammad, T. M. Paul, G. Ali and J. W. Philip. Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickel-base super-alloys. International Journal of Machine Tools and Manufacture Vol. 76 (2014), p.49–60.

DOI: 10.1016/j.ijmachtools.2013.10.002

[3] M. S. Han, B. K. Min and S. J. Lee. Geometric improvement of electrochemical discharge micro-drilling using an ultrasonic-vibrated electrolyte. Journal of Micromechanics and Microengineering Vol. 19 (2009), 065004.

DOI: 10.1088/0960-1317/19/6/065004

[4] G. Kamlage, T. Bauer, A. Ostendorf and B. N. Chichkov. Deep drilling of metals by femtosecond laser pulses. Applied Physics A: Materials Science & Processing Vol. 77 (2003), pp.307-310.

DOI: 10.1007/s00339-003-2120-x

[5] D. K. Chung, H. S. Shin, B. H. Kim, M. S. Park and C. N. Chu. Surface finishing of micro-EDM holes using deionized water. Journal of Micromechanics and Microengineering Vol. 19 (2009), 045025.

DOI: 10.1088/0960-1317/19/4/045025

[6] M. Sen and H. S. Shan. Analysis of hole quality characteristics in the electro jet drilling process. International Journal of Machine Tools and Manufacture Vol. 45 (2005), p.1706~1716.

DOI: 10.1016/j.ijmachtools.2005.03.005

[7] M. Sen and H. S. Shan. Response surface analysis of electro jet drilled holes. International Journal of Advanced Manufacturing Technology Vol. 31 (2006), p.520~527.

DOI: 10.1007/s00170-005-0196-5

[8] H. Zhang and J. W. Xu. Modeling and experimental investigation of laser drilling with jet electrochemical machining. Chinese Journal Aeronautics Vol. 23 (2010), pp.454-460.

DOI: 10.1016/s1000-9361(09)60241-7

[9] X. L. Fang, N. S. Qu, Y. D. Zhang, Z. Y. Xu and D. Zhu. Improvement of Exit Accuracy in Electrochemical Drilling by Using an Auxiliary Electrode Applied with a Positive Potential Difference. Journal of Materials Processing Technology Vol. 214(3) (2014).

DOI: 10.1016/j.jmatprotec.2013.11.008

[10] X. L. Fang, N. S. Qu, H. S. Li and D. Zhu. Enhancement of insulation durability in electrochemical drilling. International Journal of Advanced Manufacturing Technology Vol. 68 (2013), p.2005-(2013).

DOI: 10.1007/s00170-013-4803-6

[11] C. Margareta, H. P. Schulze and S. Laurentiu. Drilling of difficult-to-cut steel by electrochemical discharge machining. Materials and Manufacturing Processes Vol. 26 (2011), pp.1466-1472.

DOI: 10.1080/10426914.2011.557286

[12] J. Hung, H. Liu, Y. Chang, K. Hung and S. Liu. Development of helical electrode insulation layer for electrochemical micro-drilling. CIRP 17th . Conf. on Electro Physical and Chemical Machining (Leuven, Belgium, 9 -12 April. 2013).

DOI: 10.1016/j.procir.2013.03.045

[13] C. F. Tsai, C. C. Cheng and D. Y. Sheu. Investigating micro spherical stylus tips fabrication by electro chemical and single pulse electro discharge processes. CIRP 17th Conf. on Electro Physical and Chemical Machining (Leuven, Belgium, 9-12 April. 2013).

DOI: 10.1016/j.procir.2013.03.091

[14] D. Y. Sheu. Micro-spherical electrodes machining by EDM. Journal of Micromechanics and Microengineering Vol. 15 (2005), pp.185-189.

DOI: 10.1088/0960-1317/15/1/026

[15] D. Y. Sheu. Multi-spherical probe machining by EDM: Combining WEDG technology with one-pulse electro-discharge. Journal of Materials Processing Technology Vol. 149 (2004), pp.597-603.

DOI: 10.1016/s0924-0136(04)00217-1

[16] D. Y. Sheu and C. C. Cheng. A Hybrid Microspherical Styli Gluing and Assembling Process on Micro-EDM Mater. Materials and Manufacturing Processes Vol. 27 (2012), p.1129–1134.

DOI: 10.1080/10426914.2012.677897

[17] Y. Liu and H. S. Li. Fabrication of Micro Spherical Electrode by One Pulse Electrical Discharge Machining. 2nd Int. Conf. on Digital Manufacturing & Automation (Zhangjiajie, China, 5-7 August. 2011).

DOI: 10.1109/icdma.2011.134

[18] S. H. Ahn, S. H. Ryu, D. K. Choi and C. N. Chu. Electro-chemical micro drilling using ultra short pulses. Precision Engineering Vol. 28(2), (2004), pp.129-134.

DOI: 10.1016/j.precisioneng.2003.07.004