PMID- 37241702
OWN - NLM
STAT- PubMed-not-MEDLINE
LR  - 20230529
IS  - 2072-666X (Print)
IS  - 2072-666X (Electronic)
IS  - 2072-666X (Linking)
VI  - 14
IP  - 5
DP  - 2023 May 20
TI  - Study of Gas Film Characteristics in Electrochemical Discharge Machining and 
      Their Effects on Discharge Energy Distribution.
LID - 10.3390/mi14051079 [doi]
LID - 1079
AB  - Glass is a hard and brittle insulating material that is widely used in optics, 
      biomedicine, and microelectromechanical systems. The electrochemical discharge 
      process, which involves an effective microfabrication technology for insulating 
      hard and brittle materials, can be used to perform effective microstructural 
      processing on glass. The gas film is the most important medium in this process, 
      and its quality is an important factor in the formation of good surface 
      microstructures. This study focuses on the gas film properties and their 
      influence on the discharge energy distribution. In this study, a complete 
      factorial design of experiments (DOE) was used, with three factors and three 
      levels of voltage, duty cycle, and frequency as the influencing factors and gas 
      film thickness as the response for the experimental study, to obtain the best 
      combination of process parameters that would result in the best gas film quality. 
      In addition, experiments and simulations of microhole processing on two types of 
      glass, quartz glass and K9 optical glass, were conducted for the first time to 
      characterize the discharge energy distribution of the gas film based on the 
      radial overcut, depth-to-diameter ratio, and roundness error, and to analyze the 
      gas film characteristics and their effects on the discharge energy distribution. 
      The experimental results demonstrated the optimal combination of process 
      parameters, at a voltage of 50 V, a frequency of 20 kHz and a duty cycle of 80%, 
      that achieved a better gas film quality and a more uniform discharge energy 
      distribution. A thin and stable gas film with a thickness of 189 mum was obtained 
      with the optimal combination of parameters, which was 149 mum less than the 
      extreme combination of parameters (60 V, 25 kHz, 60%). These studies resulted in 
      an 81 mum reduction in radial overcut, a roundness error reduced by 14, and a 49% 
      increase in the depth-shallow ratio for a microhole machined on quartz glass.
FAU - Liu, Hao
AU  - Liu H
AUID- ORCID: 0000-0002-4640-4698
AD  - School of Mechanical Engineering, Xinjiang University, Urumqi 830017, China.
FAU - Xieeryazidan, Adayi
AU  - Xieeryazidan A
AD  - School of Mechanical Engineering, Xinjiang University, Urumqi 830017, China.
LA  - eng
GR  - Nos516650556/Adayi Xieeryazidan/
PT  - Journal Article
DEP - 20230520
PL  - Switzerland
TA  - Micromachines (Basel)
JT  - Micromachines
JID - 101640903
PMC - PMC10220860
OTO - NOTNLM
OT  - ECDM
OT  - discharge energy distribution
OT  - gas film characterization
OT  - machining quality
COIS- The authors declare no conflict of interest.
EDAT- 2023/05/27 09:42
MHDA- 2023/05/27 09:43
PMCR- 2023/05/20
CRDT- 2023/05/27 01:24
PHST- 2023/04/15 00:00 [received]
PHST- 2023/05/10 00:00 [revised]
PHST- 2023/05/15 00:00 [accepted]
PHST- 2023/05/27 09:43 [medline]
PHST- 2023/05/27 09:42 [pubmed]
PHST- 2023/05/27 01:24 [entrez]
PHST- 2023/05/20 00:00 [pmc-release]
AID - mi14051079 [pii]
AID - micromachines-14-01079 [pii]
AID - 10.3390/mi14051079 [doi]
PST - epublish
SO  - Micromachines (Basel). 2023 May 20;14(5):1079. doi: 10.3390/mi14051079.