Examples



mdbootstrap.com



 
Статья
2021

Electrochemical Micromachining of Copper Alloy through Hot Air Assisted Electrolyte Approach


M. SoundarrajanM. Soundarrajan, R. ThanigaivelanR. Thanigaivelan
Российский электрохимический журнал
https://doi.org/10.1134/S1023193521020117
Abstract / Full Text

The industries like automobile, electronics, medical and biomedical sectors provide scope for various types of micro products/features made up of copper material. Due to the higher ductility of copper the electrochemical micro machining (EMM) is a prominent technique owing it’s no tool wear, high accuracy, burr free and non-contact machining surface. Although enhancing of EMM performance is significant work in the micro components manufacturing industry. Hence, in this present work the hot air is mixed with aqueous citric acid (C6H8O7) electrolyte (HAME) to machine high aspect ratio micro-holes (HAR micro-hole) and the results are compared with the dry air mixed electrolyte (DAME). The process parameters such as machining voltage (Mv), Duty cycle (Dc), and electrolyte concentration (Ec) are taken into account in evaluating the machining performance. The electrolyte temperature (Et) and frequency are kept at a constant level as 36 ± 1°C and 85 Hz respectively. The machining performances are estimated by means of material removal rate (MRR), overcut (OC) and taper angle of the HAR micro hole (TAHAR-micro-hole).The MRR shows 1.43 times improvement for HAME at the parametric combination of 20 g/L, 13 V, and Dc at 90% and reduced OC by 30.4% over DAME. The TAHAR-micro-holes are found to be 21.67° and 28.19° for the DAME and HAME respectively for the above parametric combinations. At parameters combination of 30 g/L, 13 V, and 90%, the MRR shows 2.87 times higher MRR compared to DAME. Furthermore, the use of citric acid as an electrolyte and mix of hot air contributes for higher MRR and reduced OC.The field emission scanning electron microscope (FESEM) analysis is done to understand the effect of hot air mixed electrolyte on the surface topography and inner machined surfaces of a micro-hole.

Author information
  • Department of Mechanical Engineering, Muthayammal Engineering College (Autonomous), 637408, Namakkal (Dt), Rasipuram, IndiaM. Soundarrajan & R. Thanigaivelan
References
  1. Sangkee, M., Lee, D.-E., de Grave, A., De Oliveira Valente, C.M., Lin, J., and Dornfeld, D.A., Surface and edge quality variation in precision machining of single crystal and polycrystalline materials, Proc. Inst. Mech. Eng. B: J. Eng. Manuf., 2006, vol. 4, p. 479.
  2. Soundarrajan, M. and Thanigaivelan, R., Effect of coated and geometrically modified tools on performance of electrochemical micromachining, Mater. Manuf. Processes, 2020, vol. 35, no. 7, p. 1.
  3. Pratheesh Kumar, M.R., Prakasan, K., and Kalaichelvan, K., Experimental investigation and multiphysics simulation on the influence of micro tools with various end profiles on diametrical overcut of holes machined using electrochemical micromachining for a predetermined optimum combination of process parameters, Russ. J. Electrochem., 2016, vol. 52, p. 943.
  4. Soundarrajan, M. and Thanigaivelan, R., Intervening variables in electrochemical micro machining for copper, in Proc. Int. Conf. on Precision, Meso, Micro and Nano Engineering (COPEN 10), Chennai: Indian Institute of Technology Madras, 2017.
  5. Thanigaivelan, R., Arunachalam, R.M., and Drukpa, P., Drilling of micro-holes on copper using electrochemical micromachining, Int. J. Adv. Manuf. Technol., 2012, vol. 61, p. 1185.
  6. Bhattacharyya, B., Malapati, M., Munda, J., and Sarkar, A., Influence of tool vibration on machining performance in electrochemical micro-machining of copper, Int. J. Mach. Tools Manuf., 2007, vol. 47, p. 335.
  7. Pooranachandran, K., Deepak, J., Hariharan, P., and Mouliprasanth, B., in Advances in Manufacturing Processes, Vijay Sekar, K., Gupta, M., and Arockiarajan, A., Eds., Singapore: Springer, 2019.
  8. Pan Yongqiang, Zhibao Hou, and Ningsong Qu, Improvement in accuracy of micro-dimple arrays prepared by micro-electrochemical machining with high-pressure hydrostatic electrolyte, Int. J. Adv. Manuf. Tech., 2019, vol. 100, p. 1767.
  9. Baoji Ma, Peiyong Cheng, Kang Yun, and Peili Yin, Effect of magnetic field on the electrochemical machining localization, Int. J. Adv. Manuf. Technol., 2019, vol. 1, p. 8.
  10. Wang Quan Dai, Xing Xing Cai, Li Wang, Peng Yang Li, Ji Ming Xiao, and Yan Li, Investigation of the influence of ultrasonic stirring on mass transfer in the through-mask electrochemical micromachining process, China Technol.Sci., 2018, vol. 61, p. 250.
  11. Jiang Kai, Xiaoyu Wu, Jianguo Lei, Zhaozhi Wu, Wen Wu, Wen Li, and Dongfeng Diao, Vibration-assisted wire electrochemical micromachining with a suspension of B4C particles in the electrolyte, Int. J. Adv. Manuf. Technol., 2018, vol. 97, p. 3565.
  12. Zhang Chuanyun, Yongjun Zhang, Xiaolei Chen, Wei Li, and Guixian Liu, Investigation of the electrochemical dissolution behavior of tungsten during electrochemical machining, Int. J. Adv. Manuf. Technol., 2018, vol. 97, p. 3575.
  13. Malik Anup and Alakesh Manna, Investigation on the laser-assisted jet electrochemical machining process for improvement in machining performance, Int. J. Adv. Manuf. Technol., 2018, vol. 96, p. 3917.
  14. Yu Ning, Xiaolong Fang, Lingchao Meng, Yongbin Zeng, and Di Zhu, Electrochemical micromachining of titanium microstructures in an NaCl-ethylene glycol electrolyte, J. Appl. Electrochem., 2018, vol. 48, p. 263.
  15. Chen Xiaolei, Ningsong Qu, and Zhibao Hou, Electrochemical micromachining of micro-dimple arrays on the surface of Ti–6Al–4V with NaNO3 electrolyte, Int. J. Adv. Manuf. Technol., 2017, vol. 88, p. 565.
  16. Ge, Y., Zhu, Z., and Wang, D., Electrochemical dissolution behavior of the nickel-based cast superalloy K423A in NaNO3 solution, Electrochim. Acta, 2017, vol. 253, p. 379.
  17. Xu, Z., Chen, X., Zhou, Z., Qin, P., and Zhu, D., Electrochemical machining of high-temperature titanium alloy Ti60, Procedia CIRP, 2016, vol. 42, p. 125.
  18. Ayyappan, S., Sivakumar, K., and Kalaimathi, M., Electrochemical machining of 20MnCr5 alloy steel with ferric nitrate mixed aqueous NaCl electrolyte, Int. J. Mach. Mach. Mater., 2015,vol. 17, p. 79.
  19. Wang, X., Zhao, J., Hu, Y., Li, L., and Wang, C., Effects of the Lorentz force and the gradient magnetic force on the anodic dissolution of nickel in HNO3 + NaCl solution, Electrochim. Acta, 2014, vol. 117, p. 113.
  20. Thanigaivelan, R., Arunachalam, R.M., Kumar, M., and Dheeraj, B.P., Performance of electrochemical micromachining of copper through infrared heated electrolyte, Mater. Manuf. Processes, 2018, vol. 33, p. 383.
  21. Soundarrajan, M. and Thanigaivelan, R., Investigation on electrochemical micromachining (ECMM) of copper inorganic material using UV heated electrolyte, Russ. J. Appl. Chem., 2018, vol. 91, p. 1805.
  22. Tackitt Clint and Xianghe Pan, U.S. Patent Application 12/381,008, Jan. 14, 2010.
  23. Datta, A.K. and Ni, H., Infrared and hot-air-assisted microwave heating of foods for control of surface moisture, J. Food Eng., 2002, vol. 51, p. 355.
  24. Maniraj, S. and Thanigaivelan, R., Effect of electrode heating on performance of electrochemical micromachining, Mater. Manuf. Processes, 2019, vol. 34, no. 13, p. 1.
  25. Soundarrajan, M. and Thanigaivelan R., Investigation of electrochemical micromachining process using ultrasonic heated electrolyte, in Advances in Micro and Nano Manufacturing and Surface Engineering, Shunmugam, M. and Kanthababu, M., Eds., Singapore: Springer, 2019.
  26. Alkaim, A.F., Kandiel, T.A., Dillert, R., and Bahnemann, D.W., Photocatalytic hydrogen production from biomass-derived compounds: a case study of citric acid, Environ. Technol., 2016, vol. 37, p. 2687.
  27. Deconinck, D., Van Damme, S., and Deconinck, J., A temperature dependent multi-ion model for time accurate numerical simulation of the electrochemical machining process. Part II: numerical simulation, Electrochim. Acta, 2012, vol. 69, p. 120.
  28. Kolakowski, B.M. and Mester, Z., Review of applications of high-field asymmetric waveform ion mobility spectrometry (FAIMS) and differential mobility spectrometry (DMS), Analyst, 2007, vol. 132, p. 842.
  29. Alajlani, Y., Alaswad, A., Placido, F., Gibson, D., and Diyaf, A., Inorganic thin film materials for solar cell applications, in Reference Module in Materials Science and Materials Engineering, Elsevier BV, 2018.
  30. Habbache, N., Alane, N., Djerad, S., and Tifouti, L., Leaching of copper oxide with different acid solutions, Chem. Eng. J., 2009, vol. 152, p. 503.
  31. Anaum, N., Deen, K.M., Farooq, A., Ahmed, R., and Khan, I.H., Predicting the corrosion tendency of α‑brass in acidic and alkaline tap water, Int. J. Mater. Res., 2015, vol. 106, p. 92.
  32. Chen, Q.Y., Liu, J.S., Liu, Y., and Wang, Y.H., Hydrogen production on TiO2 nanorod arrays cathode coupling with bio-anode with additional electricity generation, J. Power Sources, 2013, vol. 238, p. 345.
  33. Gerd Brunner, G., Supercritical Fluid Science and Technology, chapter 12: Corrosion in Hydrothermal and Supercritical Water, Brunner, G., Ed., 2014, vol. 5, p. 591.
  34. Gattinoni, C. and Michaelides, A., Atomistic details of oxide surfaces and surface oxidation: the example of copper and its oxides, Surf. Sci. Rep., 2015, vol. 70, p. 424.
  35. Sudarsan, P. and Moorthy, S.B.K., Synergistic effect of lithium and calcium for low temperature densification and grain boundary scavenging in samarium doped ceria electrolyte, Mater. Chem. Phys., 2019, vol. 238, p. 121900.
  36. Tangphant, K., Sudaprasert, K., and Channarong, S., Mathematical modeling of electrical conductivity in electrolyte solution between two gas-evolving electrodes, Russ. J. Electrochem., 2014, vol. 50, p. 253.
  37. Lee, S.K., Hsu, H.C., and Tuan, W.H., Oxidation behavior of copper at a temperature below 300°C and the methodology for passivation, Mater. Res., 2016, vol. 19, p. 51.
  38. Navisa, J., Sravya, T., Swetha, M., and Venkatesan, M., Effect of bubble size on aeration process, Asian J. Sci. Res., 2014, vol. 7, p. 482.
  39. Batista, N.L., de Faria, M.C.M., Iha, K., de Oliveira, P.C., and Botelho, E.C., Influence of water immersion and ultraviolet weathering on mechanical and viscoelastic properties of polyphenylene sulfide-carbon fiber composites, J. Thermoplast. Compos. Mater., 2015, vol. 28, p. 340.