Problematic areas in micro-electrochemical milling of HSTR alloys
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ORIGINAL ARTICLE
Problematic areas in micro-electrochemical milling of HSTR alloys Koushik Mishra 1
&
Suraj Gupta 1 & B. Bhattacharyya 1
Received: 24 June 2020 / Accepted: 15 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Micro-electrochemical milling has capability to fabricate intricate micro-features for fulfilling the rising needs of modern manufacturing industries. Electrochemical milling is an advanced version of the ECM process, and micro-electrochemical milling is just a scaled-down approach of it. Due to the formation of a passive oxide layer on the machinable surface, electrochemical dissolution of titanium and its alloy is very much difficult and it is much more challenging with this downscaled approach. Since the last few years, researchers are trying to get the best solution for successful machining of different highstrength temperature-resistant (HSTR) alloys, e.g. titanium, nickel and cobalt alloys, etc. In this research, an attempt has been made to identify the issues that arise during micro-electrochemical milling of three different HSTR alloys which are now-a-days extensively used in the modern manufacturing industries. Furthermore, this study also deals with the best possible remedial approaches for minimizing these problems. Finally, considering all the problematic areas and their best possible remedial approaches in this study, high aspect ratio (> 10) 3D micro-features have been successfully fabricated on HSTR alloys, e.g. nickel (Nimonic-263) and cobalt alloy (Haynes-188) at the most suitable parametric combination of 7.5 V of constant DC voltage, 0.4 mm/min of feed rate and 750RPM of tool rotation. Keywords Micro-electrochemical milling . Ti6Al4V . Nimonic-263 . Haynes-188 . Problems . Strategies . Remedial approaches . High aspect ratio micro-feature
1 Introduction Electrochemical micro-machining (EMM) is capable of machining different chemically resistive and difficult-to-machine materials like titanium, nickel, cobalt and their alloys with different other superalloys which are highly applicable in the various emerging fields like aerospace, automotive, medical, optics, electronics, etc. EMM is suitable for high-accuracy machining which enables it to fabricate precise products with desired geometries without undergoing any thermal effects, tool wear and burr formation. But, in order to produce complex 3D structures or shapes having intricate structures, EMM has many limitations and is not so suitable. As the machined workpiece by EMM is the replica of tool geometry, thus, fabrication of such intricate tools is very difficult. As in the micromachining process, tool diameter is very small, so production of such intricate shapes on the tool is almost * B. Bhattacharyya [email protected] 1
Production Engineering Department, Jadavpur University, Kolkata 700032, India
impossible. Therefore, in order to overcome these difficulties, micro-electrochemical milling is introduced. In micro-electrochemical milling, the basic mechanism of material removal i
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