Manufacturing of multiscale structured surfaces

Ti-6Al-4V is an alloy that has a high strength-to-weight ratio. It is known as an alpha-beta titanium alloy with excellent corrosion resistance. This alloy has a wide range of applications, e.g., in the aerospace and biomedical industries. Examples of alpha stabilizers are aluminum, oxygen, nitrogen, and carbon, which are added to titanium. Examples of beta stabilizers are titanium–iron, titanium–chromium, and titanium–manganese. Despite the exceptional properties, the processing of this titanium alloy is challenging when using conventional methods as it is quite a hard and tough material. Nonconventional methods are required to create intricate and complex geometries, which are difficult with the traditional methods. The present study focused on machining Ti-6Al-4V using wire electrical discharge machining (WEDM) and conducting numerous experiments to establish the machining parameters. The optimal setting of the machining parameters was predicted using a multiresponse optimization technique. Experiments were planned using the response surface methodology (RSM) technique and analysis of variance (ANOVA) was used to determine the significance and contribution of the input parameters to changes in the output characteristics (cutting speed and surface roughness). The cutting speed obtained during the processing of the annealed titanium alloy using WEDM was quite large as compared to the cutting speed obtained in the case of processing the pure, quenched, and hardened titanium alloys using WEDM. The maximum cutting speed obtained while processing the annealed titanium alloy was 1.75 mm/min.

https://www.mdpi.com/1996-1944/14/9/2292/pdf

Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

With the rapid development of micro-electromechanical systems (MEMS), micro/nanoscale fabrication of 3D metallic structures with complex structures and multifunctions is becoming more and more important due to the recent trend of product miniaturization. As a promising micromanufacturing approach based on plastic deformation, micro/nanoforming shows the attractive advantages of high productivity, low cost, near-net-shape, and excellent mechanical properties, compared with other non-silicon-based micromanufacturing technologies. However, micro/nanoforming is far less established due to the so-called size effects in terms of materials models, process laws, tooling design, etc. The understanding of basic issues on micro/nanoforming is not yet mature, and it is currently a topic of rigorous investigation. Here, a systematic review on the micro/nanoforming processes of 3D structures with multifunctional properties is presented, wherein also a critical examination of the interplay between relevant length scales and size effects affecting the structural integrity of micro/mesoscale metallic systems is also provided. Finally, the challenges of micro/nanoscale fabrication are proposed, including the development trends of new micro/nanoforming processes, multiple field coupling effects, and theoretical modeling at the trans-scale.

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures.

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

A review on sustainability, health, and safety issues of electrical discharge machining

Sustainable production of micro gears combining micro reciprocated wire electrical discharge machining and precision forging

Fabrication of micro gear with intact tooth profile by micro wire electrical discharge machining

This paper presents the manufacture of micro-rotating structure combining micro reciprocated wire electrical discharge machining (wire-EDM) and multi-cutting strategy. A novel rotating spindle is developed to achieve the rotation of cylindrical workpiece and the multi-cutting strategy including rough, semi-finish, and finish machining is attempted to improve the machining removal rate (MRR) and reduce the surface roughness (SR) of micro-rotating structure. To determine proper parameters for multi-cutting process, the effects of machining parameters such as open voltage, discharge capacitance, and rotation rate on MRR and SR are studied by systematically performing experiments planed by single factor design and central composite design (CCD) of response surface methodology (RSM). Analysis of variance (ANOVA) is conducted to identify the significant factor and confirm the adequacy of the established models of MRR and SR. The mathematical models are used to predict MRR and SR within 8.18 and 8.74% prediction error compared with the additivity tests, respectively. Desirability method in RSM technique is used to determine three sets of parametric combinations for multi-cutting process, which are verified by confirmation experiments with 1.75~7.76% prediction error for MRR and 2.77~8.59% prediction error for SR. Finally, a typical microballoon probe is successfully machined with 0.435 Ra and 98.7-μm diameter by the proposed method, which provides a feasible approach for the fabrication of micro-rotating structure with high efficiency and smooth surface.

Micro reciprocated wire-EDM of micro-rotating structure combined multi-cutting strategy

The invention discloses an on-line preparation method of a side wall insulated micro tool electrode based on micro-arc oxidation, belongs to the field of micro special machining, and aims to solve the problem of poor precision of the micro machining caused by the need of the conventional side wall insulated electrode off-line preparation method for secondary clamping. The method is realized based on an on-line preparation device of the micro-arc oxidized side wall insulated micro tool electrode. Firstly, a blank of the tool electrode is fixedly arranged at the lower end of a Z shaft of a bed; a reverse copying block is connected with a power signal output end of a high-frequency pulse power supply; the Z shaft of a machine tool rotates at a high speed to perform electrical discharge on-line grinding on a block electrode with the tool electrode blank; then the side wall of the tool electrode is subjected to micro-arc oxidation on-line insulation preparation; an insulating ceramic film is oxidized on the outer surface of the tool electrode blank; on-line preparation of the micro-arc oxidized side wall insulated micro tool electrode is realized. The method is applicable to on-line preparation of the tool electrode.

On-line preparation method of side wall insulated micro tool electrode based on micro-arc oxidation

Study on Micro Reciprocated Wire-EDM for Complex Indexing Structure

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