Marcin Grabowski

Experimental Research on Electrochemically Assisted Microturning Process

In the paper the concept of electrochemically assisted microturning process was presented. This is a hybrid machining process in which the microcutting directly removes the material while the electrochemical passivation process is changing the conditions of cutting. The experimental part consist of description of passive layer formation process on 304 steel samples and results discussion of passive layer thickness and mechanical properties measurement with ellipsometry and nanoindentation technique.

Design of instrumentation and software for precise laser machining

The paper concerns the design of instrumentation and software for precise laser machining. Application of advanced laser beam manipulation instrumentation enables noticeable improvement of cut quality and material loss. This factors have significant impact on process efficiency and cutting edge quality by means of machined part size and shape accuracy, wall taper, material loss reduction (e.g. diamond) and time effectiveness. The goal can be reached by integration of laser drive, observation and optical measurement system, beam manipulation system and five axis mechanical instrumentation with use of advanced tailored software enabling full laser cutting process control and monitoring.

Research on Unconventional Methods of Cylindrical Micro-Parts Shaping

One can state that special place in group of micromanufacturing methods are connected with application of unconventional methods, such as electrochemical (EC) and electrodischarge (ED) micromilling, because of their high efficiency in shaping 3D structures. In the paper result of cylindrical tools manufacturing for EC and ED-micro milling process will be discussed. The special attention will be paid for electrochemical etching, electrodischarge turning and some hybrid methods application for micro-tools manufacturing

Some aspects of precise laser machining - Part 2: Experimental

The paper describes the role of laser beam polarization on quality of laser beam machined cutting tool edge. In micromachining the preparation of the cutting tools in play a key role on dimensional accuracy, sharpness and the quality of the cutting edges. In order to assure quality and dimensional accuracy of the cutting tool edge it is necessary to apply laser polarization control. In the research diode pumped Nd:YAG 532nm pulse laser was applied. Laser beam polarization used in the research was linear (horizontal, vertical). The goal of the carried out research was to describe impact of laser beam polarization on efficiency of the cutting process and quality of machined parts (edge, surface) made of polycrystalline diamond (PCD) and cubic boron nitride (cBN). Application of precise cutting tool in micromachining has significant impact on the minimum uncut chip thickness and quality of the parts. The research was carried within the INNOLOT program funded by the National Centre for Research and Development.

The state of the art in electrochemical machining process modeling and applications

The Electrochemical Machining process (ECM) can be applied for shaping advanced conductive materials which are difficult or impossible for machining using conventional methods. In electrochemical machining the workpiece is an anode and material is removed as a result of electrochemical reactions. This mechanism of material removal makes it possible to obtain high metal removal rate and good surface layer quality when machining parts made of super-alloys, alloys, steels and some composite materials on metallic base. The very important but difficult problem is ECM process mathematical modeling because the phenomena occurring into interelectrode gap are very complicated. In order to simplify the mathematical modeling it is necessary to introduce some modification of the ECM sinking process by: application of pulse voltage (Pulse ECM) often correlated with electrodes vibration, ECM machining with universal electrodes. The other important directions of ECM process development are: manufacturing processes by electrochemical deposition and some hybrid processes as electrochemical-electrodischare or electrochemical grinding machining.The Electrochemical Machining process (ECM) can be applied for shaping advanced conductive materials which are difficult or impossible for machining using conventional methods. In electrochemical machining the workpiece is an anode and material is removed as a result of electrochemical reactions. This mechanism of material removal makes it possible to obtain high metal removal rate and good surface layer quality when machining parts made of super-alloys, alloys, steels and some composite materials on metallic base. The very important but difficult problem is ECM process mathematical modeling because the phenomena occurring into interelectrode gap are very complicated. In order to simplify the mathematical modeling it is necessary to introduce some modification of the ECM sinking process by: application of pulse voltage (Pulse ECM) often correlated with electrodes vibration, ECM machining with universal electrodes. The other important directions of ECM process development are: manufacturing processes by el...

A Study on Microturning with Electrochemical Assistance of the Cutting Process

The paper investigated an electrochemically-assisted microturning process. Depending on the variant of electrochemical assistance, material can be removed with simultaneous electrochemical and mechanical action or electrochemical assistance can change the conditions of the cutting by changing the mechanical properties of the machined material. The experimental part includes discussion of the study methodology and a comparison of straight turning results in the case of machining 1.4301 stainless steel with and without electrochemical assistance. Based on this study, we can confirm that electrochemical assistance brings significant benefits in both variants, especially when the depth-of-cut is in the range of 1 µm.