Skip to main content
SpringerLink
Log in

Investigation on parametric effects on groove profile generated on Ti1023 titanium alloy by jet electrochemical machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Ti1023 titanium alloy is widely used in various industries due to the excellent synthetic performance, but its machining processes are still being developed. Jet electrochemical machining, combining the advantages of electrochemical machining and numerical control technique, becomes a promising machining method for Ti1023 titanium alloy. Aiming to explore the feasibility for jet electrochemical machining of surface structure on Ti1023 titanium alloy, this work systematically studied the mechanism and parametric effects in a jet electrochemical machining process via simulation and experiments. Anodic polarization of Ti1023 titanium alloy in NaCl electrolyte reveals that the oxide layer removal potential reaches 4.7 V vs. SCE, and a long time application of high voltage is required to remove the oxide layer and achieve the desired dissolution state. A novel three-dimensional model accounting for this polarization behavior was developed to predict the machining performance. Through simulation and experiments, the process conditions were optimized as 24 V of applied voltage, 0.6 mm of inter-electrode gap, 2.1 L min−1 of electrolyte flow rate, and 25 μm s−1 of nozzle traveling rate. Using the selected parameters, a surface structure with an “S” shape can be efficiently machined on Ti1023 titanium alloy by jet electrochemical machining with controlled multi-dimensional nozzle motion.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wilson JF (1971) Practice and theory of electrochemical machining, 2nd edn. John Wiley & Sons Inc, New York

    Google Scholar 

  2. Bannard J (1977) Electrochemical machining. J Appl Electrochem 7:1–29

    Article  Google Scholar 

  3. Rajurkar KP, Zhu D, McGeough JA, Kozak J, DeSilva AKM (1999) New developments in electro-chemical machining. CIRP Ann 48:568–579

    Google Scholar 

  4. Rajurkar KP, Sundaram MM, Malshe AP (2013) Review of electrochemical and electrodischarge machining. Procedia CIRP 6:13–26

    Article  Google Scholar 

  5. Sarkar S, Mitra S, Bhattacharyya B (2004) Mathematical modeling for controlled electrochemical deburring (ECD). J Mater Process Technol 147:2241–2246

    Article  Google Scholar 

  6. Spieser A, Ivanov A (2015) Design of an electrochemical micromachining machine. Int J Adv Manuf Technol 78:737–752

    Article  Google Scholar 

  7. Hinduja S, Pattavanitch J (2016) Experimental and numerical investigations in electro-chemical milling. CIRP J Manuf Sci Technol 12:79–89

    Article  Google Scholar 

  8. Datta M, Romankiw LT, Vigliotti DR, Gutfeld von RJ (1989) Jet and laser-jet electrochemical micromachining of nickel and steel. J Electrochem Soc 136:2251–2256

    Article  Google Scholar 

  9. Kunieda M, Yoshida M, Yoshida H, Akamatsu Y (1993) Influence of micro indents formed by electro-chemical jet machining on rolling bearing fatigue life. ASME PED 64:693–699

    Google Scholar 

  10. Kozak J, Rajurkar KP, Balkrishna R (1996) Study of electrochemical jet machining process. J Manuf Sci Eng 118:490–498

    Article  Google Scholar 

  11. Yoneda K, Kunieda M (1996) Numerical analysis of cross section shape of micro-indents formed by the electrochemical jet machining. J Jpn Soc Electr Mach Eng 29:1–8 (in Japanese)

    Google Scholar 

  12. Natsu W, Ikeda T, Kunieda M (2007) Generating complicated surface with electrolyte jet machining. Precis Eng 31:33–39

    Article  Google Scholar 

  13. Natsu W, Ooshiro S, Kunieda M (2008) Research on generation of three dimensional surface with micro-electrolyte jet machining. CIRP J Manuf Sci Technol 1:27–34

    Article  Google Scholar 

  14. Kai S, Sai H, Kunieda M, Izumi H (2012) Study on electrolyte jet cutting. Procedia CIRP 1:627–632

    Article  Google Scholar 

  15. Hackert-Oschatzchen M, Meichsner G, Zinecker M, Martin A, Schubert A (2012) Micro machining with continuous electrolytic free jet. Precis Eng 36:612–619

    Article  Google Scholar 

  16. Kawanaka T, Kato S, Kunieda M, Murray JW, Clare AT (2014) Selective surface texturing using electrolyte jet machining. Procedia CIRP 13:345–349

    Article  Google Scholar 

  17. Kawanaka T, Kunieda M (2015) Mirror-like finishing by electrolyte jet machining. CIRP Manuf Technol 64:237–240

    Article  Google Scholar 

  18. Hackert-Oschatzchen M, Pual R, Kowalick M, Martin A, Meichsner G, Schubert A (2015) Multiphysics simulation of the material removal in jet electrochemical machining. Procedia CIRP 31:197–202

    Article  Google Scholar 

  19. Hackert-Oschatzchen M, Pual R, Martin A, Meichsner G, Lehnert N, Schubert A (2015) Study on the dynamic generation of the jet shape in jet electrochemical machining. J Mater Process Technol 223:240–251

    Article  Google Scholar 

  20. Walker JC, Kamps TJ, Lam JW, Mitchell-Smith J, Clare AT (2017) Tribological behaviour of an electrochemical jet machined textured Al-Si automotive cylinder liner material. Wear 376-377:1611–1621

    Article  Google Scholar 

  21. Speidel A, Mitchell-Smith J, Walsh DA, Hirsch M, Clare AT (2016) Electrolyte jet machining of titanium alloy using novel electrolyte solutions. Procedia CIRP 42:367–372

    Article  Google Scholar 

  22. Mitchell-Smith J, Clare AT (2016) Electrochemical jet machining of titanium: overcoming passivation layers with ultrasonic assistance. Procedia CIRP 42:379–383

    Article  Google Scholar 

  23. Yuan Y, Han LH, Huang D, Su JJ, Tian ZQ, Tian ZW, Zhan DP (2015) Electrochemical micromachining under mechanical motion mode. Electrochim Acta 183:3–7

    Article  Google Scholar 

  24. Kozak J, Osman HM, Dabrowski L (1988) Theoretical and experimental investigation for profile electrolytic machining with rotating electrode. In: Proceeding of the 27th MTDR, p 281–286

  25. Schubert A, Hackert-Oschätzchen M, Martin A, Winkler S, Kuhn D, Meichsner G, Zeidler H, Edelmann J (2016) Generation of complex surfaces by superimposed multi-dimensional motion in electrochemical machining. Procedia CIRP 42:384–389

    Article  Google Scholar 

  26. Klocke F, Zeis M, Klink A, Veselovac D (2012) Technological and economical comparison of roughing strategies via milling, EDM and ECM for titanium- and nickel-based Blisks. Procedia CIRP 2:98–101

    Article  Google Scholar 

  27. Lohrengel MM, Rataj KP, Munninghoff T (2016) Electrochemical machining mechanisms of anodic dissolution. Electrochim Acta 201:348–453

    Article  Google Scholar 

  28. Hinduja S, Kunieda M (2013) Modelling of ECM and EDM processes. CIRP Annals Manuf Technol 62:775–797

    Article  Google Scholar 

  29. Wang DY, Zhu ZW, He B, Ge YC, Zhu D (2017) Effect of the breakdown time of a passive film on the electrochemical machining of rotating cylindrical electrode in NaNO3 solution. J Mater Process Technol 239:251–257

    Article  Google Scholar 

  30. Weinmann M, Stolpe M, Weber O, Busch R, Natter H (2015) Electrochemical dissolution behavior of Ti90Al6V4 and Ti60Al40 used for ECM applications. J Solid State Electrochem 19:485–495

    Article  Google Scholar 

  31. Gonzalez JEG, Mirza-Rosca JC (1999) Study of the corrosion of titanium and some of its alloys for biomedical and dental implant applications. J Electroanal Chem 471:109–115

    Article  Google Scholar 

  32. Jiang ZL, Dai X, Norby T, Middleton H (2011) Investigation of titanium based on a modified point defect model. Corros Sci 53:815–821

    Article  Google Scholar 

  33. Sazou D, Saltidou K, Pagitsas M (2012) Understanding of the effect of bromides on the stability of titanium oxide films based on a point defect model. Electrochim Acta 76:48–61

    Article  Google Scholar 

Download references

Acknowledgements

Additionally, Weidong Liu especially wishes to thank Xin Zhang for the patience, care, and support over the past years.

Funding

This work was supported by National Key R&D Program of China (No.2018YFB1107900), the National Natural Science Foundation of China (No. 51575383), and Natural Science Foundation of Tianjin City (No. 18JCQNJC04100).

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Tianjin University-Peiyang Park Campus, 31-291, Yaguan Road, Tianjin, 300350, China

    Weidong Liu, Zhen Luo, Zuming Liu, Kangbai Li, Jianxiang Xu & Sansan Ao

  2. Collaborative Innovation Center of Advanced Ship and Deep-Sea Exploration, Shanghai, 200240, China

    Zhen Luo

  3. Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI, 48109, USA

    Yang Li

Authors
  1. Weidong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhen Luo
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zuming Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Kangbai Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jianxiang Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Sansan Ao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Zhen Luo or Sansan Ao.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, W., Luo, Z., Li, Y. et al. Investigation on parametric effects on groove profile generated on Ti1023 titanium alloy by jet electrochemical machining. Int J Adv Manuf Technol 100, 2357–2370 (2019). https://doi.org/10.1007/s00170-018-2804-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2804-1

Keywords

Search

Navigation