SURFACE ROUGHNESS DECREASE IN THE ELECTROCHEMICAL-ULTRASONIC HYBRID MACHINING
Keywords:
electrochemical machining, ultrasound, roughness, modeling, simulation
Abstract
The paper deals with the presentation of a method for numerical modeling and simulation of the effect of the ultrasonic component in the electrochemical-ultrasonic hybrid machining. The focus is on removing surface microgeometry peaks beneath the passivated layer and the surface smoothing mechanism. A shear fatigue resistance calculation was performed for C120 steel. After defining the input parameters, the numerical modeling and simulation were conducted using the specialized software program Comsol Multiphysics. A scanning electron microscope analysis of the processed surfaces was carried out, followed by a study of the influence of each machining parameter (current density, ultrasonic power, machining time).
References
1. Enciu, C.C., Pârvu, G.M., Ghiculescu, L.D., Opran, C.G., Application of Micro Electrical Discharge Machining and Electrochemical Machining in Manufacturing of Micro-Electrochemical Systems: A Review, Macromolecular Symposia, ISSN:1022-1360, eISSN:1521-3900, Vol. 404, 6 pagini, (2022).
2. Marinescu, N.I., Ghiculescu, D., Popa, L., Pîrnău, C., Marinescu, R., Ene, G.M., Procese tehnologice cu fascicule, oscilații și jeturi, Volumul 3, Tehnologii cu unde ultrasonice, ISBN 978-606-23-0984-8, Editura Printech, Cod CNCSIS 54, București, (2019).
3. Insoon, Y., et. al., Micro ECM with Ultrasonic Vibrations Using a Semi-cylindrical Tool, International Journal of Precision Engineering and Manufacturing, Vol. 10, No. 2, p. 5-10, (2009).
4. Mitchell-Smith, J., Clare, A.T., ElectroChemical Jet Machining of Titanium: Overcoming Passivation Layers with Ultrasonic Assistance, Elsevier, Procedia CIRP 42, p. 379-383, (2016).
5. Nicoara, D., Hedes, A., Sora, I., Ultrasonic Enhancement of an Electrochemical Machining Process, Proceedings of the 5th WSEAS International Conference on Applications of Electrical Engineering, Prague, Czech Republic, Vol. 5, p. 213-218, (2006).
6. Zhang, Y., Investigation Into Current Efficiency For Pulse Electrochemical Machining Of Nickel Alloy, Industrial and Management Systems Engineering, M.S. Thesis, University of Nebraska - Lincoln, (2010).
7. Kozak, J., & Dabrowski, L., Electrochemical Machining of Difficult-to-Cut Materials, In DAAAM International Scientific Book, pp. 571-590, (2013).
8. Bhattacharyya, B., & Munda, J., Experimental investigation on the influence of electrochemical machining parameters on machining rate and accuracy in micromachining domain, International Journal of Machine Tools and Manufacture, 43(13), 1301-1310, (2003).
9. Drobota, V., Rezistenta materialelor, Editura tehnica, 1982.
10. Ghiculescu, D., Chapter 5 - Ultrasonically Aided Electrical Discharge Machining, Manufacturing Technology Reasearch, Electrical Discharge Machining - Types, Technologies and Applications, M.P. Jahan Editor, Nova Science Publishers, ISBN:978-1-63483-598-5, (2015).
11. Enciu, C.C., Research on hybrid electrochemical-ultrasonic finishing machining, Teză de doctorat, UNSTPB, (2024).
2. Marinescu, N.I., Ghiculescu, D., Popa, L., Pîrnău, C., Marinescu, R., Ene, G.M., Procese tehnologice cu fascicule, oscilații și jeturi, Volumul 3, Tehnologii cu unde ultrasonice, ISBN 978-606-23-0984-8, Editura Printech, Cod CNCSIS 54, București, (2019).
3. Insoon, Y., et. al., Micro ECM with Ultrasonic Vibrations Using a Semi-cylindrical Tool, International Journal of Precision Engineering and Manufacturing, Vol. 10, No. 2, p. 5-10, (2009).
4. Mitchell-Smith, J., Clare, A.T., ElectroChemical Jet Machining of Titanium: Overcoming Passivation Layers with Ultrasonic Assistance, Elsevier, Procedia CIRP 42, p. 379-383, (2016).
5. Nicoara, D., Hedes, A., Sora, I., Ultrasonic Enhancement of an Electrochemical Machining Process, Proceedings of the 5th WSEAS International Conference on Applications of Electrical Engineering, Prague, Czech Republic, Vol. 5, p. 213-218, (2006).
6. Zhang, Y., Investigation Into Current Efficiency For Pulse Electrochemical Machining Of Nickel Alloy, Industrial and Management Systems Engineering, M.S. Thesis, University of Nebraska - Lincoln, (2010).
7. Kozak, J., & Dabrowski, L., Electrochemical Machining of Difficult-to-Cut Materials, In DAAAM International Scientific Book, pp. 571-590, (2013).
8. Bhattacharyya, B., & Munda, J., Experimental investigation on the influence of electrochemical machining parameters on machining rate and accuracy in micromachining domain, International Journal of Machine Tools and Manufacture, 43(13), 1301-1310, (2003).
9. Drobota, V., Rezistenta materialelor, Editura tehnica, 1982.
10. Ghiculescu, D., Chapter 5 - Ultrasonically Aided Electrical Discharge Machining, Manufacturing Technology Reasearch, Electrical Discharge Machining - Types, Technologies and Applications, M.P. Jahan Editor, Nova Science Publishers, ISBN:978-1-63483-598-5, (2015).
11. Enciu, C.C., Research on hybrid electrochemical-ultrasonic finishing machining, Teză de doctorat, UNSTPB, (2024).
Published
2025-03-31
How to Cite
Enciu, C., Ghiculescu, L., Alupei Cojocariu, O., & Lazar, M. (2025). SURFACE ROUGHNESS DECREASE IN THE ELECTROCHEMICAL-ULTRASONIC HYBRID MACHINING. Nonconventional Technologies Review, 29(1). Retrieved from http://revtn.ro/index.php/revtn/article/view/506
Section
Articles
