Shape control in micro borehole generation by EMM with the assistance of vibration of tool
Shape control in micro borehole generation by EMM with the assistance of vibration of tool
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DOI：
10.1016/j.precisioneng.2013.08.004
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发表时间：
2014
影响因子：
3.6
通讯作者：
B. Ghoshal;B. Bhattacharyya
中科院分区：
文献类型：
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作者：
B. Ghoshal;B. Bhattacharyya
电化学微加工因其具有无刀具磨损、无应力/毛刺、高MRR、表面光洁、可加工复杂形状、不受硬度影响等优点而日益受到重视。过切和锥度成形是微细孔加工中的主要问题。为了更好地理解这一过程，本文建立了EMM的电路模型，实验MRR与理论MRR吻合较好。研究了过切度随电压、脉冲频率、刀具振动幅度和刀具振动频率的变化规律。为了降低微小孔的过切和锥角，用倒锥刀对加工区域进行了模拟，并通过实际实验验证了微小孔加工过程中合理的形状控制。研究了不同进给速度和不同加工次数下微喷嘴角度的变化规律，以实现锥形刀具微细加工过程中的形状控制。结果表明，反向锥度和正向锥度工具均可用来生成无锥度的微特征，即钻孔。
Electrochemical micromachining (EMM) is gaining importance day by day due its advantages that include no tool wear, absence of stress/burr, high MRR, bright surface finish and ability to machine complex shapes regardless of hardness. Overcut and taper formation is the main problem during micro borehole machining. In this paper, an electrical circuit model of EMM is presented for better understanding of the process and experimental MRR is found to be in good agreement with theoretical MRR. In the present set up variation of overcut with voltage, pulsed frequency, vibration amplitude of tool and vibration frequency of tool are investigated. To reduce overcut and taper angle of micro borehole, machining zone is simulated with a reversed taper tool and verified by practical experiments for proper shape control during micro borehole generation. Variation of micro nozzle angle with different feed rates and different times of machining are also investigated for the shape control during micromachining with conical tool. Finally, it has been shown that both reversed taper and forward taper tool can be used for generation of taper less micro features i.e. boreholes.