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Effect of Electrode Wire Position in Capillary Drilling
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DOI：10.1149/1945-7111/ae62af.png)
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Abstract
En 中文
Capillary drilling (CD) is a crucial method for producing deep small holes in hard-to-machine metals. In practice, the electrode wire frequently undergoes vibration and radial offset, but its effects on hole geometries remain unclear. In addition, the electrode wire is generally required to be retracted axially into the capillary, but the underlying mechanism is not well understood. This study investigates the influence of electrode wire position on the CD process using experiments and multiphysics simulations. The results show that the vibration of the electrode wire depends on the electrolyte pressure and the dimensional matching between the wire and capillary. The vibration of the electrode wire exerts negligible effects on the hole geometries compared to a stationary, centrally located wire. The electrode wire radial offset causes the machined hole to become elliptical and inclined. The wire offset produces a non-axisymmetric electric field, resulting in uneven material removal and electrolyte pressure distribution, which eventually bends the capillary and causes inclined tool feeding. Increasing the wire axial retraction distance allows the electric and flow fields to distribute uniformly, thus mitigating or even eliminating the adverse effects of wire offset. These findings offer insights into cathode tool design and process optimization for CD.
Keywords:
Capillary drilling
Electrode wire position
Wire vibration
Wire offset
Process optimization
Journal
IF:
3.3
Papers:
3.3W
Citations:
9.4W
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Cited Papers