Hits:

Affiliation of Author(s):Shandong University, Weihai

Journal:The International Journal of Advanced Manufacturing Technology

Key Words:Electrochemical machining · Ultrasonic assistant · Integration of electrochemical drilling and grinding · Small holes · Selective laser melting · Hastelloy X

Abstract:To enhance the precision of machining small hole structures in parts produced by Selective Laser Melting (SLM), a new method named ultrasonic assisted electrochemical drilling and grinding (UA-ECDG) technology with coated abrasive tube electrode is proposed. Compared with traditional electrochemical drilling, this method has obvious advantages. Firstly, the use of tube electrode to actively spray electrolyte improves the efficiency of electrolyte renewal and machining products elimination. Secondly, through the establishment of grinding force control model, the grinding effect of abrasive coating is matched with electrochemical removal to remove passivation film with minimal damage on substrate, which can improve machining efficiency and localization while ensuring the surface quality. Thirdly, following simulation guidance, ultrasonic vibration is implemented to further optimize the grinding effect and flow field. The periodic vibration disturbs the flow field and reduces the probability of substrate damage caused by long-term contact of abrasive particles. Moreover, machining experiments were also conducted on machining parameters to obtain better machining results. Finally, small hole arrays with diameters of 1350 ± 10 μm and side wall roughness of 0.65 μm were obtained on a 2-mm-thick SLMed Hastelloy X workpiece, and the side walls of small holes were vertical and smooth, demonstrating the practicality of the method.

All the Authors:Wenchao Guan, Tong Shu, Kan Wang

First Author:Yipeng Qin

Indexed by:Research Paper

Correspondence Author:Yong Liu

Document Code:10.1007/s00170-024-12978-1

Document Type:Journal article

Volume:130

Page Number:5181-5197

ISSN No.:0268-3768

Translation or Not:no

Date of Publication:4534-04-01