Modeling and investigation on multi-wire electrochemical machining (MWECM) assisted with different flushing strategies. (September 2020)

• Record Type: Journal Article
• Authors: Maity, S.; Debnath, S.; Bhattacharyya, B.
• Is Part Of: Journal of manufacturing processes. Volume 57(2020)
• Page Start: 857
• Page End: 870
• Publication Date: 2020-09
• Subjects: Multi-wire electrochemical machining -- Flushing by axial electrolyte flow and PZT vibration -- Mathematical model; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2020.07.024
• Languages: English
• ISSNs: 1526-6125

Abstract

Graphical abstract: Highlights: Suitable MWECM setup has been indigenously developed along with a mathematical model for predicting slit width. Three different flushing strategies have been compared in terms of maximum feed rate, slit width and machining accuracy. Best parameters of axial flushing combined with PZT vibration has ensured higher wire feed, accuracy and lower slit width. The validated model has showed combined flushing strategy as ideal flushing when maximum feed rate is still in high range. Micro slit array and array of complex micro feature have successfully been fabricated with developed setup. Abstract: With growing technological needs, downscaling and productivity of fabricating micro features has become very crucial. In this context, multi-wire electrochemical machining (MWECM), an advanced form of wire electrochemical machining (WECM) process, is recently being introduced. This anodic dissolution process which is still at its primordial stage produces array micro features in a single run. The research work, portrayed here, is focused on the development of suitable MWECM setup for the fabrication of array micro slits with desired criteria. A mathematical model has been formulated to find out the correlation between process parameters and the width of the micro slit that has been validated later. Depending upon indigenously developed setup, attempts have been made for finding the best flushing parameter settings when axial electrolyte flow, PZT vibration and newly introduced combined approach consisting of those two have been used during experiments. For this, experimentations have been carried out with tungsten wire having a diameter of 50 μm on 100 μm thick stainless steel (SS 304) sheets. Moreover, the experimental results have been analyzed for gaining further insight into the effects of different electrolyte flushing strategies with varying wire feed rate on required output criteria. A comparison has been established between different electrolyte flushing strategies introduced on multi-wire electrodes during experiments for selecting the most suitable technique for cleaning the machining gap. Also, an array of micro slits and complex micro features using the MWECM process considering the best process parameter setting as obtained have been fabricated in order to explore the process efficiency.