The purpose of this study is to improve flow of electrolyte due to metal deposition on the inner surface of the pipe, which causes short circuit. In order to prevent metal deposition, the main metal in the working fluid was deposited and removed, and short-circuiting was reduced. As a result,the life of the electrolyte was extended successfully.

As an advanced electrochemical machining (ECM) method, electrolyte jet machining (EJM) is a potential alternative for machining of titanium alloy. However, oxide layer usually forms in traditional water-based electrolyte, which prevents uniform dissolution and consequently deteriorates the machining accuracy. To overcome the oxide layer, a novel electrolyte, NaCl ethylene glycol (EG)-based solution, was proposed for EJM of titanium alloy in this work. Effect of machining current, nozzle translating speed, and nozzle translating path interval on machining performance using this novel electrolyte was investigated. Furthermore, the high viscosity of EG-based electrolyte makes it difficult to form hydraulic jump in EJM, which limits the application of this novel electrolyte in electrolytic miro-machining of titanium alloy. To overcome this limit, high electrolyte temperature was proposed in this work. The combined effect of electrolyte temperature and nozzle diameter on the formation of hydraulic jump and machining performance was investigated. The results show that high electrolyte temperature enables usage of small nozzle in EJM with EG-based electrolyte for miniaturization of machined geometry without side effect on machining performance.

Large discharging current and short pulse duration has positive influences on electrical discharging machining (EDM), especially on improving machining accuracy and material removal rate. In fact, it is hard to generate large discharging current and short pulse duration via conventional generators. This research is devoted to design a novel generator which can generate large current and short duration for EDM. Simulation and experiments are used to verify the ability of proposed generator.

This paper reports the stress distribution inside of the workpiece under ultrasonically assisted orthogonal cutting (UAC) condition. It is widely noted that UAC reduces the average cutting force and cutting heat generation. However it is fundamentally difficult to observe the dynamic cutting process phenomenon with ultrasonic frequency band. In this research, stress field inside of the workpiece during UAC was observed by combining method consists of the pulse emitting source synchronized with ultrasonically vibrating cutting edge and the photoelastic method. In this report, it was observed the stress distribution change with tool vibration speed for various cutting depth. The results showed that intermittent cutting condition affected not only vibration condition and feed speed but also cutting depth. The amount of remaining uncut caused by elastic deformation of work will effect on ultrasonic cutting condition.