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| 1 | Wire electrochemical machining with axial electrolyte flushing for titanium alloy显示文摘Titanium and its alloys have found very wide application in aerospace due to their excellent characteristics although their processing is still a challenge. Electrochemical machining is an important issue in the fabrication of titanium and titanium alloys. Wire electrochemical machining (WECM) is mainly used for workpiece cutting under the condition of different thickness plates. It has a great advantage over wire electro-discharge machining, which is the absence of heat-affected zone around the cutting area. Moreover, the wire electrode in WECM could be used repetitively because it is not worn out. Thus, much attention has been paid to WECM. The effective way of removing electrolysis products is of importance to WECM. In this paper, the axial electrolyte flushing is presented to WECM for removing electrolysis products and renewing electrolyte. The Taguchi experiment is conducted to optimize the machining parameters, such as wire feedrate, machining voltage, electrolyte concentration, etc. Experimental results show that WECM with axial electrolyte flushing is a promising issue in the fabrication of titanium alloy (TC1). The feasibility of multi-wire electrochemical machining is also demonstrated to improve the machining productivity of WECM. | Qu Ningsong Fang Xiaolong Li Wei Zeng Yongbin Zhu Di | 2013 | Chinese Journal of Aeronautics2013，26，1： | 19 |
| 2 | Electrochemical micromachining of micro-dimple arrays on cylindrical inner surfaces using a dry-film photoresist显示文摘The application of surface textures has been employed to improve the tribological performance of various mechanical components. Various techniques have been used for the application of surface textures such as micro-dimple arrays, but the fabrication of such arrays on cylindrical inner surfaces remains a challenge. In this study, a dry-film photoresist is used as a mask during through-mask electrochemical micromachining to successfully prepare micro-dimple arrays with dimples 94 lm in diameter and 22.7 lm deep on cylindrical inner surfaces, with a machining time of 9 s and an applied voltage of 8 V. The versatility of this method is demonstrated, as are its potential low cost and high efficiency. It is also shown that for a fixed dimple depth, a smaller dimple diameter can be obtained using a combination of lower current density and longer machining time in a passivating sodium nitrate electrolyte. | Qu Ningsong Chen Xiaolei Li Hansong Zeng Yongbin | 2014 | Chinese Journal of Aeronautics2014，27，4： | 12 |
| 3 | Simulation and experimental investigation of inner-jet electrochemical grinding of GH4169 alloy显示文摘GH4169 alloy is one of the most commonly used materials in aero engine turbine blades,but its machinability is poor because of its excellent strength at high temperatures. Electrochemical machining(ECM) has become a common method for machining this alloy and other difficult-tomachine materials. Electrochemical grinding(ECG) is a hybrid process combining ECM and conventional grinding. In this paper, investigations conducted on inner-jet ECG of GH4169 alloy are described. Two types of inner-jet ECG grinding wheels were used to machine a flat bottom surface.The machining process was simulated using COMSOL software, and machining gaps under different machining parameters were obtained. In addition, maximum feed rates and maximum material removal rates under different machining parameters were studied experimentally. The maximum sizes and the uniformity of the distributions of the gaps machined by the two grinding wheels were compared. The effects of different applied voltages on the machining results were also investigated. | Hansong LI Shuxing FU Qingliang ZHANG Shen NIU Ningsong QU | 2018 | Chinese Journal of Aeronautics2018，31，3： | 9 |
| 4 | Electrochemical machining of burn-resistant Ti40 alloy显示文摘This study investigates the feasibility of using electrochemical machining(ECM) to produce critical aeroengine components from a new burn-resistant titanium alloy(Ti40), thereby reducing costs and improving efficiency relative to conventional mechanical machining.Through this, it is found that an aqueous mix of sodium chloride and potassium bromide provides the optimal electrolyte and that the surface quality of the Ti40 workpiece is improved by using a pulsed current of1 k Hz rather than a direct current.Furthermore, the quality of cavities produced by ECM and the overall material removal rate are determined to be dependent on a combination of operating voltage, electrolyte inlet pressure, cathode feeding rate and electrolyte concentration.By optimizing these parameters, a surface roughness of 0.371 lm has been achieved in conjunction with a specific removal rate of more than 3.1 mm3/A?min. | Xu Zhengyang Liu Jia Zhu Dong Qu Ningsong Wu Xiaolong Chen Xuezhen | 2015 | Chinese Journal of Aeronautics2015，28，4： | 6 |
| 5 | Abrasive-assisted Nickel Electroforming Process with Moving Cathode显示文摘In traditional electroforming process for revolving parts with complex profiles, the drawbacks on surface of deposits, such as pinholes and nodules, will lead to varying physical and mechanical properties on different parts of electroformed components. To solve the problem,compositely moving cathode is employed in abrasive-assisted electroforming of revolving parts with complicated profiles. The cathode translates and rotates simultaneously to achieve uniform friction effect on deposits without drawbacks. The influences of current density and translation speed on the microstructure and properties of the electroformed nickel layers are investigated. It is found that abrasive-assisted electroforming with compound cathode motion can effectively remove the pinholes and nodules,positively affect the crystal nucleation, and refine the grains of layer. The increase of current density will lead to coarse microstructure and lower micro hardness, from 325 HV down to 189 HV. While, faster translational linear speed produces better surface quality and higher micro hardness, from 236 HV up to 283 HV. The weld-ability of the electroformed layers are also studied through the metallurgical analysis of welded joints between nickel layer and 304 stainless steel. The electrodeposited nickel layer shows fine performance in welding. The novel compound motion of cathode promotes the mechanical properties and refines the microstructure of deposited layer. | Jianhua REN Zengwei ZHU Chunqiu XIA Ningsong QU Di ZHU | 2017 | Chinese Journal of Mechanical Engineering2017，30，2： | 4 |
| 6 | Mechanical electrodeposition of bright nanocrystalline nickel显示文摘A new mechanical electrodeposition technology was proposed, and nanocrystalline nickel deposit with bright and smooth surface was prepared in the bath without any additive agents. Unlike traditional methods, the novel technology employed dynamical hard particles to continuously polish the cathode surface and disturb the nearby solution during electrodepositing. Experimental results showed that the polishing effect of hard particles can effectively prevent the hydrogen bubbles and impurities from adhering on the deposit surface and avoid the production of pits, pinholes and nodules. Furthermore, comparing with the deposit prepared by traditional methods, the one prepared by the novel technology was substantially refined with grain size ranging from 30 to 80 nm. Every diffraction peak's intensity of the deposit was reduced, the preferential orientation degree of (200) decreased and those of (111) and (220) increased. The microhardness notably increased. The magnetic properties were also changed with decreased saturation magnetization and increased coercive force. It was also found that variation of current density and cathode rotational speed could affect the structure and properties of the nickel deposits prepared by this technology. | ZHU ZengWei ZHU Di QU NingSong | 2008 | Science China(Technological Sciences)2008，51，7： | 3 |
| 7 | Electrochemical micromachining of microgroove arrays on phosphor bronze surface for improving the tribological performance显示文摘A high friction coefficient and a low wear rate of contacted surfaces are essential elements to friction pairs between the stator and the rotor in ultrasonic motors. It has been shown that surface textures have a significant effect on improving the tribological performance of friction pairs.In this paper, microgroove arrays are introduced to the stator surface for improving the tribological performance of friction pairs between the stator and the rotor in ultrasonic motors. Microgrooves were fabricated on a phosphor bronze surface by through-mask electrochemical micromachining(TMEMM). Parameters, namely, the electrolyte inlet pressure, applied voltage, pulse duty cycle,and frequency, were varied to investigate their influences on the dimensions and morphology of the microgrooves. Results showed that the width and depth of the microgrooves were strongly affected by the applied voltage and frequency, while the morphology of the microgrooves was dependent on the electrolyte inlet pressure and the pulse duty cycle. Compared with a smooth surface, the friction coefficient increased from 0.245 to 0.334 and less abrasion was obtained when a surface was textured with microgrooves of which the width and depth were 185.6 and 57.6 lm,respectively. Microgroove arrays might play an important role in enhancing the performance of ultrasonic motors. | Xuan ZHOU Ningsong QU Zhibao HOU Gai ZHAO | 2018 | Chinese Journal of Aeronautics2018，31，7： | 3 |
| 8 | Improvements to machining surface quality by controlling the flow direction of electrolyte during electrochemical sinking and milling of titanium alloy显示文摘Electrochemical milling is eminently suitable for machining aerospace parts(which usually have complex structures) because of its great flexibility. However,titanium alloys are particularly sensitive to changes in the flow field,which often cause severe pitting corrosion of the machined surface. Although electrochemical sinking and milling(ESM) can restrict the flow of electrolyte and reduce pitting corrosion,the quality of the machined surface is not ideal because the latter are susceptible to stray corrosion. To reduce such corrosion and improve the surface quality,the internal flow channel of the tool electrode and the cutting depth were investigated thoroughly. Extensive experiments revealed that stray corrosion could be reduced significantly and surface quality improved by controlling the electrolyte flow direction in the machining area,which was achieved by changing the style of the internal flow channel of the tool electrode. These reductions in corrosion and surface roughness were achieved using a tool electrode with a triangular internal flow channel. In addition,the main components and micro-hardness of the machined surface were close to that of the TB6 titanium alloy substrate,which helped to maintain the inherent high strength of the titanium alloy. The surface of the workpiece changed from being hydrophilic to being hydrophobic,which reduced the flow resistance. | LIU Yang QU NingSong | 2020 | Science China(Technological Sciences)2020，63，12： | 2 |
| 9 | Electrochemical micromachining of microstructures of micro hole and dim- ple array 显示文摘 | Zhu Di Qu Ningsong Li Hansong | 2009 | CIRP Annals-Manufacturing Technology2009，58，1： | 1 |
| 10 | Generating micro-dimples array on the hard chrome coated surface by modified through mask electrochemical micromachin- ing显示文摘 | Qian Shuangqing Zhu Di Qu Ningsong | 2010 | The International Journal of Advanced Manufac- turing Technology2010，47，12： | 1 |
| 11 | Fabrication of high-aspect-ratio electrode array by combining UV-LIGA with micro electro-discharge machining 显示文摘 | Hu Yangyang Zhu Di Qu Ningsong | 2009 | Microsyst Technol2009，15，： | 1 |
| 12 | Electrochemical drilling inclined holes using wedged electrodes 显示文摘 | Wang Wei Zhu Di Qu Ningsong | 2010 | In- ternational Journal of Advanced Manufacturing Technolo- gy2010，47，9101112： | 1 |
| 13 | Synthesis ofnanocrystalline nickel in pulse deposition显示文摘 | LEI Weining ZHU Di QU Ningsong | 2002 | Transactions of theInstitute of Metal Finishing2002，80，6： | 1 |
| 14 | Abrasive polishing assisted nickel electroforming process显示文摘 | Zhu Di Zhu Zengwei Qu Ningsong | 2006 | CIRP Annals-Manufacturing Technology2006，55，1： | 1 |
| 15 | Electrodeposition of bright nickel coating under perturbation of hard particles显示文摘 | Zengwei Zhu Di Zhu Ningsong Qu Weining Lei | 2006 | Materials and Design2006，，6： | 1 |
| 16 | Improving machining accu- racy of electrochemical machining blade by optimization of cathode feeding directions显示文摘 | Qu Ningsong Xu Zhengyang | 2013 | The International Journal of Advanced Mamffacturing Technology2013，68，5： | 1 |
| 17 | Theoretical and Experimental Investigation on Electrochemical Micro--machining显示文摘 | Zhang Zhaoyang Zhu Di Qu Ningsong | 2003 | Microsystem Technologies2003，13，7： | 1 |
| 18 | Experimental investigation of rotary sinking electrochemical discharge milling with high-conductivity salt solution and non-pulsed direct current显示文摘Electrochemical milling is a modified technique of traditional electrochemical machining(ECM)that can be used to manufacture some helicopter transmission system parts.The use of rotary tools and an inner-jet electrolyte supply pattern can greatly improve the material removal rate(MRR)in a single pass.However,the feed speed is generally limited to minimize the tool wear.To increase the MRR,electrical discharge machining(EDM)is introduced into the electrochemical milling process.The tool rotation is employed to interrupt the discharge and the high-conductivity salt solution and non-pulsed direct current power supply are also adopted to increase ECM,eventually,a new machining method is proposed,which can be called rotary sinking electrochemical discharge milling(RSECD milling).The mechanism of it is explored in this study by analyzing the machined current,MRR,surface morphology,and tool wear at different applied voltages and feed speeds.Besides,the RSECD milling using the tool with a larger diameter is also conducted to further verify the effectiveness.In particular,the MRR can be increased by 742.5%when using the tool with a diameter of 20 mm at the applied voltage of 20 V. | Xiaokang YUE Yuehong MA Ningsong QU Hansong LI | 2023 | Chinese Journal of Aeronautics2023，36，2： | 1 |
| 19 | Theoretical and experimental investigation on electrochemical micromachining显示文摘 | Zhaoyang Zhang Di Zhu Ningsong Qu Minghuan Wang | 2007 | Microsystem Technologies2007，，7： | 1 |
| 20 | Generatingmicro-dimples array on the hard chrome-coated surface bymodified through mask electrochemical micromachining显示文摘 | Qian Shuangqian Zhu Di Qu Ningsong | 2010 | The International Journal of Advanced ManufacturingTechnology2010，47，912： | 1 |
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