Drilling 3D holes with a chained ball magnet electrode in ECM

Drilling 3D holes with a chained ball magnet electrode in ECM | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Drilling 3D holes with a chained ball magnet electrode in ECM Shihyoung Ryu, Seungzoon Kim, Mingyu Jeong This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7492315/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 16 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract This paper presents a novel method for fabricating 3D holes using a chained ball magnet (CBM) electrode in electrochemical drilling (ECD) process. The CBM electrode provides an extended magnetic control range and is driven by two cylindrical magnets mounted on separate three-axis motion stages. A simple and effective method for fabricating the CBM module is introduced, incorporating an insulation technique to prevent short circuits during ECD. Optimal ECD parameters such as applying voltage, pulse frequency, and pulse duty ratio were experimentally investigated. The magnetic forces acting on the CBM were analytically formulated, and their validity was verified through experimental tests and comparison with ANSYS Maxwell simulations. Ultrasonic vibrations were applied to the electrolyte to enhance sludge removal and reduce machining time. The proposed method successfully fabricated a blind deep hole in Al 6061 alloy with a 3.8 mm entrance diameter and a high aspect ratio (A/R) of 20, as well as complex 3D holes. This technique shows strong potential for practical applications, as it imposes virtually no limitations on the achievable hole length or shape. 3D hole CBM Magnetic manipulation ECD Full Text Cite Share Download PDF Status: Published Journal Publication published 16 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 29 Oct, 2025 Reviewers agreed at journal 07 Sep, 2025 Reviewers invited by journal 06 Sep, 2025 Editor assigned by journal 05 Sep, 2025 First submitted to journal 03 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7492315","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":511221845,"identity":"b1300ef2-116a-4ddc-b0da-1b9d16d41497","order_by":0,"name":"Shihyoung Ryu","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA2UlEQVRIiWNgGAWjYHAC9g8SPDZyjDOgXAkitLAxWMikGZOopcLmcGIDTClBLeYzcswe3Mg5nN48u/eYBEONHYPk7AP4tcjcyDE3nHEmPbdxzrk0CYZjyQzSfAn4tUhI5BhIS/ZY5zYCrZNgYDvAIMdDwGFgLX//MaczgrX8I06LmYQEj3MCWAtj2wEGaYJaeJ4VG0jwpBk2zjljbJHYl8wj2UNIC3vyxgfAqJQ3nN1jeOPDNzs5iTMEtDAIJEBowwYgAWQTchYQ8B+A0PKElY6CUTAKRsFIBQA8qTktNp99rAAAAABJRU5ErkJggg==","orcid":"","institution":"chonbuk national university","correspondingAuthor":true,"prefix":"","firstName":"Shihyoung","middleName":"","lastName":"Ryu","suffix":""},{"id":511221846,"identity":"bf2125b8-ae69-4f36-b625-9ee6527d8c65","order_by":1,"name":"Seungzoon Kim","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Seungzoon","middleName":"","lastName":"Kim","suffix":""},{"id":511221847,"identity":"46eff5c0-a848-4949-a618-60f1ddb4cc5b","order_by":2,"name":"Mingyu Jeong","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Mingyu","middleName":"","lastName":"Jeong","suffix":""}],"badges":[],"createdAt":"2025-08-30 02:55:34","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7492315/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7492315/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-17353-2","type":"published","date":"2026-01-16T16:29:00+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":100615896,"identity":"98def4cb-5364-4230-800e-15bd20cdaaaa","added_by":"auto","created_at":"2026-01-19 17:37:59","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":853064,"visible":true,"origin":"","legend":"","description":"","filename":"ManuscriptRyu.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7492315/v1_covered_1dc5fecc-955e-4683-a13b-cd7419fb135d.pdf"}],"financialInterests":"","formattedTitle":"Drilling 3D holes with a chained ball magnet electrode in ECM","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"3D hole, CBM, Magnetic manipulation, ECD","lastPublishedDoi":"10.21203/rs.3.rs-7492315/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7492315/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis paper presents a novel method for fabricating 3D holes using a chained ball magnet (CBM) electrode in electrochemical drilling (ECD) process. The CBM electrode provides an extended magnetic control range and is driven by two cylindrical magnets mounted on separate three-axis motion stages. A simple and effective method for fabricating the CBM module is introduced, incorporating an insulation technique to prevent short circuits during ECD. Optimal ECD parameters such as applying voltage, pulse frequency, and pulse duty ratio were experimentally investigated. The magnetic forces acting on the CBM were analytically formulated, and their validity was verified through experimental tests and comparison with ANSYS Maxwell simulations. Ultrasonic vibrations were applied to the electrolyte to enhance sludge removal and reduce machining time. The proposed method successfully fabricated a blind deep hole in Al 6061 alloy with a 3.8 mm entrance diameter and a high aspect ratio (A/R) of 20, as well as complex 3D holes. This technique shows strong potential for practical applications, as it imposes virtually no limitations on the achievable hole length or shape.\u003c/p\u003e","manuscriptTitle":"Drilling 3D holes with a chained ball magnet electrode in ECM","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-09-12 19:13:14","doi":"10.21203/rs.3.rs-7492315/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2025-10-29T09:53:20+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-09-08T01:31:49+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-09-06T16:09:38+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-09-05T06:54:45+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-09-03T22:40:20+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"654664fe-83c4-430f-9c3c-bdd6e384288d","owner":[],"postedDate":"September 12th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-01-19T17:02:35+00:00","versionOfRecord":{"articleIdentity":"rs-7492315","link":"https://doi.org/10.1007/s00170-025-17353-2","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-01-16 16:29:00","publishedOnDateReadable":"January 16th, 2026"},"versionCreatedAt":"2025-09-12 19:13:14","video":"","vorDoi":"10.1007/s00170-025-17353-2","vorDoiUrl":"https://doi.org/10.1007/s00170-025-17353-2","workflowStages":[]},"version":"v1","identity":"rs-7492315","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7492315","identity":"rs-7492315","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}