Machining over-cut

As discussed below, the hydrodynamic regime is responsible for the increase in the machining over-cut and for the formation of heat affected zones around the microhole. This is an undesired effect and one should try to avoid machining in this situation. Strategies to reduce this regime are presented in Chapter 7. 

The material removal rate and the machining over-cut increase with the machining voltage [100,105] and electrolyte concentration [105,133], which also increases the probability of wire breaking [105]. Polarising the wire as a cathode generally results in higher material removal rates than for a wire polarised as an anode. 

An efficient method to decrease the machining over-cut involves adding abrasive particles into the electrolyte [133] or the use a pulsed voltage supply. At the same time surface roughness is decreased and can reach values below 1 pm. 

A further increase in the tool-electrode rotation improves the channel quality (Fig. 7.14). The sidewall taper angle of the microchannel profile decreases to almost 0° and the machining over-cut is also reduced. This effect is due to the improved electrolyte flow, promoting chemical etching of the glass. 

The fleshing is done on a multiroller machine that pulls the hide over a rotating blade, similar to a milling machine that cuts off the flesh from the inside of the hide. The machine includes a mbber roUer that holds the hide near the rotating fleshing blades. Through the adjustment of the clearances or the thickness of the hides and the resiUence of the mbber roUer the flesh is effectively removed regardless of the differences in the thickness of the hide from back to belly and flanks. 

The gap between laboratory wear testing and industrial appHcation trials is extremely difficult to bridge, since there is often Httie or no control over testing in the industrial environment. Despite these limitations, several examples of industrial successes involving ion implanted tools have been reported and blind tests of nitrogen-implanted machine tools have been performed, including tool taps, dies, punches, and TiN coated WC cutting inserts (106). 

You place the device on the cement sidewalk and step on it. This will turn me over in the fourth dimension so that I will be rotated into a mirror image of myself The machine rotates me about a plane that cuts through my body from head to groin. Watch. ... 

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