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Abrasive enhanced electrochemical slurry jet micro-machining: Comparative experiments and synergistic effects |
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| Affiliation: | 1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing 210016, China;2. Department of Mechanical and Industrial Engineering, University of Toronto, 5 King''s College Road, Toronto, ON, Canada M5S 3G8;3. Department of Mechanical and Industrial Engineering, Ryerson University, 350 Victoria Street, Toronto, ON, Canada M5B 2K3;1. Department of Mechanical and Industrial Engineering, University of Toronto, 5 King''s College Road, Toronto, ON, Canada M5S 3G8;2. Department of Mechanical and Industrial Engineering, Ryerson University, 350 Victoria Street, Toronto, ON M5B 2K3, Canada;1. Professorship Micromanufacturing Technology, Faculty of Mechanical Engineering, Technische Universität Chemnitz, D-09107 Chemnitz, Germany;2. Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Strasse 88, D-09126 Chemnitz, Germany;1. Department of Mechanical and Industrial Engineering, University of Toronto, 5 King''s College Road, Toronto, ON, Canada M5S 3G8;2. Department of Mechanical and Industrial Engineering, Ryerson University, 350 Victoria Street, Toronto, ON, Canada M5B 2K3;1. Technische Universität Chemnitz, Professorship Micromanufacturing Technology, 09107 Chemnitz, Germany;2. Fraunhofer Institute for Machine Tools and Forming Technology, 09126 Chemnitz, Germany |
| Abstract: | Abrasive enhanced electrochemical slurry-jet machining (ESJM) is presented as a new approach to the micro-machining of metals using a combination of abrasive slurry-jet machining (ASJM) and electrochemical jet machining (ECJM). A novel ESJM prototype was developed to generate a charged slurry jet consisting of a mixture of Al2O3 abrasive particles and an electrolytic solution of NaCl and NaNO3. A DC potential of 30 V was applied between the nozzle and specimen. A series of micro-channels were machined in Stellite 12 using ASJM, ECJM and ESJM processes to investigate the relative effects of erosion and anodic dissolution on the material removal rate and surface finish in the combined process of ESJM. The results illustrated that the ESJM process results in significantly greater target mass loss rate than the separate erosion and corrosion processes. The magnitude of the synergistic effect on the rate of mass loss was found to vary from positive to negative as the erosion component increased with increasing particle kinetic energy (jet pressure) and particle concentration. The roughness of the channels machined using ESJM was between that obtained with ASJM and ECJM. The roughness decreased as the erosion component of the total mass loss increased. |
| Keywords: | Abrasive slurry jet Electrochemical micro-machining Electrochemical jet micro-machining Solid particle erosion Stellite |
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