{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2025,10,12]],"date-time":"2025-10-12T03:15:11Z","timestamp":1760238911185,"version":"build-2065373602"},"reference-count":13,"publisher":"MDPI AG","issue":"9","license":[{"start":{"date-parts":[[2022,8,27]],"date-time":"2022-08-27T00:00:00Z","timestamp":1661558400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100001809","name":"the National Natural Science Foundation of China","doi-asserted-by":"publisher","award":["51875328","ZR2019MEE013"],"award-info":[{"award-number":["51875328","ZR2019MEE013"]}],"id":[{"id":"10.13039\/501100001809","id-type":"DOI","asserted-by":"publisher"}]},{"name":"the Natural Science Foundation of Shandong Province","award":["51875328","ZR2019MEE013"],"award-info":[{"award-number":["51875328","ZR2019MEE013"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Micromachines"],"abstract":"<jats:p>In this study, a new method of ultrasonic high-frequency percussion (UH-FP) is proposed. Ultra-fine and ultra-long copper tube electrodes cannot be fabricated by traditional processing methods, and the copper tube electrodes fabricated by UH-FP can be used in the process of rotary EDM for microfine holes. The UH-FP setup has been established based on an ultrasonic device, a workpiece chucking and rotation device, and a workpiece reciprocating motion device. In this work, by studying the principle of ultrasonic processing, the processing principle and mechanism of ultra-fine and ultra-long copper tube electrode preparation by ultrasonic high-frequency percussion is proposed. The effects of processing parameters (i.e., rotational speed, feed rate, working gap, percussion amplitude) on surface roughness are evaluated quantitatively. Experimental results show that the proposed method could complete the core leach of the core-containing copper tube electrodes after drawing, while improving surface quality. Some surface defects such as cracks, scratches and folds were completed removed, further improving the mechanical performance of processed parts. The surface roughness (Ra) of 0.091 \u03bcm was obtained from the initial 0.46 \u03bcm under the optimal processing parameters of 800 rpm tube rotational speed, 200 mm\/min platform feed speed, 0.13 mm machining gap, 0.15 mm percussion amplitude, and 32 min machining time. The method shows potential for manufacturing copper tube electrodes for a wide range of industrial applications.<\/jats:p>","DOI":"10.3390\/mi13091405","type":"journal-article","created":{"date-parts":[[2022,8,29]],"date-time":"2022-08-29T03:34:56Z","timestamp":1661744096000},"page":"1405","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Fabrication of Ultra-Fine and Ultra-Long Copper Tube Electrodes by Ultrasonic High-Frequency Percussion"],"prefix":"10.3390","volume":"13","author":[{"given":"Xiajunyu","family":"Zhang","sequence":"first","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Yugang","family":"Zhao","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Hanlin","family":"Yu","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Zhihao","family":"Li","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Chuang","family":"Zhao","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Guangxin","family":"Liu","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Chen","family":"Cao","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Qian","family":"Liu","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Zhilong","family":"Zheng","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Dandan","family":"Zhao","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China"}],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"1968","published-online":{"date-parts":[[2022,8,27]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"492","DOI":"10.1007\/s001700200052","article-title":"Electrochemical drilling of Inconel superalloy with acidified sodium chloride electrolyte","volume":"19","author":"Sharma","year":"2002","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"560","DOI":"10.1016\/j.cja.2015.06.021","article-title":"Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling","volume":"29","author":"Zhang","year":"2016","journal-title":"Chin. J. Aeronaut."},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"2049","DOI":"10.1016\/j.matpr.2021.11.250","article-title":"Sustainability and recent trends in micro- electric discharge machining (\u03bc-EDM): A state-of-the-art review","volume":"57","author":"Pandey","year":"2021","journal-title":"Mater. Today Proc."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"877","DOI":"10.1016\/j.protcy.2016.08.196","article-title":"Experimental Investigations Into EDM Behaviours of En41b Using Copper and Brass Rotary Tubular Electrode","volume":"25","author":"Vincent","year":"2016","journal-title":"Procedia Technol."},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"2970","DOI":"10.1016\/j.matpr.2019.07.167","article-title":"Fabrication of High Aspect Ratio WC-Co Micro Electrodes for -EDM Application","volume":"18","author":"Kk","year":"2019","journal-title":"Mater. Today Proc."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"227","DOI":"10.1007\/s11740-008-0094-4","article-title":"Machining of micro rotational parts by wire electrical discharge grinding","volume":"2","author":"Uhlmann","year":"2008","journal-title":"Prod. Eng."},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"143","DOI":"10.1016\/j.jmatprotec.2016.03.023","article-title":"Fabrication of micro rod electrode by electrical discharge grinding using two block electrodes","volume":"234","author":"Qingfeng","year":"2016","journal-title":"J. Mater. Process. Technol."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"162","DOI":"10.1016\/j.jmapro.2014.09.003","article-title":"Fabrication of micro spherical electrode by one pulse EDM and their application in electrochemical micromachining","volume":"17","author":"Yong","year":"2015","journal-title":"J. Manuf. Process."},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"251","DOI":"10.1016\/S0924-0136(03)00261-9","article-title":"Fabrication of cylindrical micro-pins with various diameters using DC current density control","volume":"141","author":"Lim","year":"2003","journal-title":"J. Mater. Process. Technol."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"590","DOI":"10.1016\/j.procir.2020.01.171","article-title":"Micro ball-ended tips stylus fabrication with pipe-electrode by micro-EDM process","volume":"95","author":"Twh","year":"2020","journal-title":"Procedia CIRP"},{"key":"ref_11","first-page":"1004","article-title":"Evaluation of process parameters of ultrasonic treatment of 1 bacterial suspensions","volume":"17","author":"Hulsmans","year":"2010","journal-title":"Mediterr. J. Soc. Sci."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"105970","DOI":"10.1016\/j.engfailanal.2021.105970","article-title":"Investigating the nodulation mechanism of copper cathode based on microscopic approach: As a punch failure factor","volume":"133","author":"Shojaei","year":"2021","journal-title":"Eng. Fail. Anal."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"153032","DOI":"10.1016\/j.apsusc.2022.153032","article-title":"Synergistic mechanism and decopperization kinetics for copper anode slime via an integrated ultrasound-sodium persulfate process","volume":"589","author":"Liu","year":"2022","journal-title":"Appl. Surf. Sci."}],"container-title":["Micromachines"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2072-666X\/13\/9\/1405\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,11]],"date-time":"2025-10-11T00:16:20Z","timestamp":1760141780000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2072-666X\/13\/9\/1405"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2022,8,27]]},"references-count":13,"journal-issue":{"issue":"9","published-online":{"date-parts":[[2022,9]]}},"alternative-id":["mi13091405"],"URL":"https:\/\/doi.org\/10.3390\/mi13091405","relation":{},"ISSN":["2072-666X"],"issn-type":[{"type":"electronic","value":"2072-666X"}],"subject":[],"published":{"date-parts":[[2022,8,27]]}}}