Experimental Study On Machining Of Micro Channels At Metallic Surface Using Abrasive Electrochemical Jet Machining

The micro groove structures on the surface of the metallic parts are capable of providing those parts some additional optical,physical and mechanical properties.The micro groove structure has been proved to have a wide application in the fields of micro cutting tool,new energy battery,micro tool electrode,MEMS device and micro mold etc.Abrasive enhanced electrochemical jet machining(AECJM)is a new type of non-traditional machining process combining abrasive erosion and electrochemical anodic dissolution to remove metals simultaneously.The advantages of AECJM involve low cost,high removal rate and good surface quality.In this work,the study of machining micro grooves using AECJM process has been performed on stainless steel.Firstly,an experimental setup,which includes pressure supply,displacement system,power supply and jet system,was designed and built up accordingly.A hydraulic driven diaphragm metering pump was chosen as the pressure supply device due to its advantages of good wear resistance and corrosion resistance.The setup also integrated a pulsation damper and a jewel nozzle with micro-sized in diameter,which make this setup be able to output a micro sized abrasive electrochemical jet with high pressure.Consequently,the material removal mechanism of abrasive water jet machining(AWJM),electrochemical jet machining(ECJM)and abrasive electrochemical jet machining were analyzed theoretically.This work introduced the material removal models of AWJM,ECJM and AECJM theoretically.The characteristics and advantages of CFD and multi physical field simulation software,e.g.Fluent and COMSOL,have been demonstrated.Those two systems have been applied to simulate the jet flow field and electric field accordingly.Afterwards,the corrosion of metals under the condition of abrasive particle impact has been discussed.At last stage,experimental machining of micro grooves on stainless steel using AECJM has been conducted.The influences of machining voltage,machining gap,jet pressure,particle concentration and solution concentration on machining results were investigated.A metallographic microscope and a profilometer have been used to observe the surface morphology and measure the surface profile and roughness of the machined micro grooves.Finally,micro grooves with complex patterns were machined in order to exhibit the capability of the presented process.