scholarly journals Transient simulation of electrochemical machining processes for manufacturing of surface structures in high‐strength materials

2021 ◽  
Author(s):  
Sascha Loebel ◽  
Mike Zinecker ◽  
Philipp Steinert ◽  
Andreas Schubert
Keyword(s):  
Electrochemical Machining ◽  
High Strength ◽  
Surface Structures ◽  
Transient Simulation ◽  
Machining Processes

scholarly journals (ECS 234th) Multiphysics Modeling Prediction of Electrochemically Machined Through-Hole Geometries

2018 ◽  
Author(s):  
Brian Skinn ◽  
Tim Hall ◽  
Stephen Snyder ◽  
KP Rajurkar ◽  
Jennings E. Taylor
Keyword(s):  
Electrochemical Machining ◽  
High Strength ◽  
Mirror Image ◽  
Simulation Software ◽  
Manufacturing Technology ◽  
Tungsten Alloy ◽  
Machining Processes ◽  
Predictive Tool ◽  
Multiphysics Simulation ◽  
Through Hole

Electrochemical machining (ECM) is a manufacturing technology that allows metal to be precisely removed by electrochemical oxidation and dissolution into an electrolyte solution. ECM is suited for machining parts fabricated from “difficult to cut” materials and/or parts with complicated and intricate geometries. In ECM, the workpiece is the anode and the tool is the cathode in an electrochemical cell; by relative movement of the shaped tool into the workpiece, the mirror image of the tool is “copied” or machined into the workpiece. Compared to mechanical or thermal machining processes where metal is removed by cutting or electric discharge/laser machining, respectively, ECM does not suffer from tool wear or result in a thermally damaged surface layer on the workpiece. Consequently, ECM has strong utility as a manufacturing technology for fabrication of a wide variety of metallic parts and components, and includes machining, deburring, boring, radiusing and polishing processes. ECM provides particular value in that application is straightforward to high strength/tough and/or work-hardening materials such as high strength steel, chrome-copper alloy (C18200), nickel alloy (IN718), cobalt-chrome alloy (Stellite 25) and tantalum-tungsten alloy (Ta10W), since the material removal process involves no mechanical interaction between the tool and the part. A variety of production applications are envisioned as well suited for ECM techniques.One notable difficulty with ECM, common to a variety of manufacturing operations, is an inability to predict a priori the tool and process parameters required in order to satisfy the final specifications of the fabricated part. In this talk, Faraday will present results from ongoing development work of a physics-based design platform to predict optimal ECM tool shape using commercially available multiphysics simulation software. This predictive capability is anticipated to dramatically shorten the process/tooling development cycle, eliminating much or all of the iterative prototyping necessary in the absence of a predictive tool. The main focus of this talk will be a comparison of through-holes fabricated by CM in flat plate and/or tube geometries to those predicted by multiphysics simulation. The various physics included in the models to enable accurate simulations will be discussed, along with any (semi-)empirical simplifying assumptions made to accelerate execution of the simulations. The overarching objective of the current and future work, to demonstrate accurate modeling of ECM through-hole features of progressively increasing experimental complexity, will also be presented.

scholarly journals Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density

Micromachines ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 261 ◽  
Author(s):  
Matin Yahyavi Zanjani ◽  
Matthias Hackert-Oschätzchen ◽  
André Martin ◽  
Gunnar Meichsner ◽  
Jan Edelmann ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Process Control ◽  
Current Density ◽  
Electrochemical Machining ◽  
High Strength ◽  
Special Focus ◽  
Machining Processes ◽  
Product Features ◽  
Mechanical Machining ◽  
Jet Electrochemical Machining

Jet electrochemical machining (Jet-ECM) is a flexible method for machining complex microstructures in high-strength and hard-to-machine materials. Contrary to mechanical machining, in Jet-ECM there is no mechanical contact between tool and workpiece. This enables Jet-ECM, like other electrochemical machining processes, to realize surface layers free of mechanical residual stresses, cracks, and thermal distortions. Besides, it causes no burrs and offers long tool life. This paper presents selected features of Jet-ECM, with special focus on the analysis of the current density during the machining of single grooves in stainless steel EN 1.4301. Especially, the development of the current density resulting from machining grooves intersecting previous machining steps was monitored in order to derive systematic influences. The resulting removal geometry is analyzed by measuring the depth and the roughness of the machined grooves. The correlation between the measured product features and the monitored current density is investigated. This correlation shows that grooves with the desired depth and surface roughness can be machined by controlling current density through the adjustment of process parameters. On the other hand, current density is sensitive to the changes of working gap. As a consequence of the changes of workpiece form and size for the grooves intersecting premachined grooves as well as the grooves with a lateral gap, working gap, and current density change. By analyzing monitoring data and removal geometry results, the suitability of current density inline monitoring to enable process control is shown, especially with regards to manufacture products that should comply with tight predefined specifications.

Micro Machining of Nonconductive Al2O3 Ceramic on Developed TW-ECSM Setup

2012 ◽  
pp. 167-177
Author(s):  
Alakesh Manna ◽  
Amandeep Kundal
Keyword(s):  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Actual Condition ◽  
Test Results ◽  
Machining Performance ◽  
Machining Processes ◽  
Al2o3 Ceramic ◽  
Advanced Ceramic

Advanced ceramic materials are gradually becoming very important for their superior properties such as high hardness, wear resistance, chemical resistance, and high strength to weight ratio. But machining of advanced ceramic like Al2O3-ceramics is very difficult by any well known and common machining processes. Normally, cleavages and triangular fractures generate when machining of these materials is done by traditional machining methods. It is essential to develop an efficient and accurate machining method for processing advanced ceramic materials. For effective machining of Al2O3-ceramics, a traveling wire electrochemical spark machining (TW-ECSM) setup has been developed. The developed TW-ECSM setup has been utilized to machine Al2O3 ceramic materials and subsequently test results are utilized to analyze the machining performance characteristic. Different SEM photographs show the actual condition of the micro machined surfaces. The practical research analysis and test results on the machining of Al2O3 ceramics by developed TWECSM setup will provide a new guideline to the researchers and manufacturing engineers.

Micro Machining of Nonconductive Al2O3 Ceramic on Developed TW-ECSM Setup

2011 ◽  
Vol 1 (2) ◽  
pp. 46-55
Author(s):  
Alakesh Manna ◽  
Amandeep Kundal
Keyword(s):  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Actual Condition ◽  
Test Results ◽  
Machining Performance ◽  
Machining Processes ◽  
Al2o3 Ceramic ◽  
Advanced Ceramic

Advanced ceramic materials are gradually becoming very important for their superior properties such as high hardness, wear resistance, chemical resistance, and high strength to weight ratio. But machining of advanced ceramic like Al2O3-ceramics is very difficult by any well known and common machining processes. Normally, cleavages and triangular fractures generate when machining of these materials is done by traditional machining methods. It is essential to develop an efficient and accurate machining method for processing advanced ceramic materials. For effective machining of Al2O3-ceramics, a traveling wire electrochemical spark machining (TW-ECSM) setup has been developed. The developed TW-ECSM setup has been utilized to machine Al2O3 ceramic materials and subsequently test results are utilized to analyze the machining performance characteristic. Different SEM photographs show the actual condition of the micro machined surfaces. The practical research analysis and test results on the machining of Al2O3 ceramics by developed TWECSM setup will provide a new guideline to the researchers and manufacturing engineers.

Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication

2019 ◽  
Author(s):  
Arul Kulandaivel ◽  
Senthil Kumar Santhanam
Keyword(s):  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
High Heat ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Turning Operation ◽  
Minimum Quantity

Abstract Turning operation is one of the most commonly used machining processes. However, turning of high strength materials involves high heat generation which, in turn, results in undesirable characteristics such as increased tool wear, irregular chip formation, minor variations in physical properties etc. In order to overcome these, synthetic coolants are used and supplied in excess quantities (flood type). The handling and disposal of excess coolants are tedious and relatively expensive. In this proposed work, Water Soluble Cutting Oil suspended with nanoparticles (Graphene) is used in comparatively less quantities using Minimum quantity lubrication (MQL) method to improve the quality of machining. The testing was done on Turning operation of Monel K500 considering the various parameters such as the cutting speed, feed and depth of cut for obtaining a surface roughness of 0.462μm and cutting tool temperature of 55°C for MQL-GO (Graphene oxide) process.

Comparison of Fuzzy and Crisp Versions of an AHP and TOPSIS Model for Nontraditional Manufacturing Process Ranking Decision

2019 ◽  
Vol 18 (02) ◽  
pp. 167-192 ◽  
Author(s):  
Mustafa Yurdakul ◽  
Yusuf Tansel İç
Keyword(s):  
Fuzzy Ahp ◽  
Level Structure ◽  
Selection Procedure ◽  
High Strength ◽  
Fine Tuning ◽  
Attribute Selection ◽  
Machining Processes ◽  
Ranking Model ◽  
Order Preference ◽  
Fuzzy Weights

Nontraditional manufacturing processes (NTMPs) are especially preferred when it is necessary to machine very small and delicate parts, obtain complex shapes or process very hard and high strength materials. New NTMPs are developed continually and the total number of NTMPs being used in the machining industry is increasing so that ranking and selection of the most proper NTMP requires multi-level and systematic models. [M. Yurdakul and C. Cogun, Development of a multi-attribute selection procedure for non-traditional machining processes, Proc. Inst. Mech. Eng. J. Eng. Manuf.217 (2003) 993–1009] developed such an NTMP ranking model. The developed NTMP ranking model in [M. Yurdakul and C. Cogun, Development of a multi-attribute selection procedure for non-traditional machining processes, Proc. Inst. Mech. Eng. J. Eng. Manuf.217 (2003) 993–1009] had a two-level structure and used crisp Analytical Hierarchy Process (AHP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) together to rank feasible NTMPs. This study aims to replace crisp (nonfuzzy) versions of the AHP and TOPSIS with the fuzzy ones. Application of the fuzzy NTMP ranking model is illustrated and its results are compared with the ones obtained in [M. Yurdakul and C. Cogun, Development of a multi-attribute selection procedure for non-traditional machining processes, Proc. Inst. Mech. Eng. J. Eng. Manuf.217 (2003) 993–1009] to evaluate the significance of the differences in ranking results. The comparisons show that using fuzzy AHP and TOPSIS approaches instead of the crisp ones in the ranking model provided considerable ranking differences. The fuzzy NTMP ranking model is studied furthermore in the paper by updating the NTMP list and fine-tuning fuzzy weights of the pertinent attributes.

Abrasive Assisted Electrochemical Machining of Al-B4C Nanocomposite

2015 ◽  
Vol 787 ◽  
pp. 523-527 ◽  
Author(s):  
K. Rajkumar ◽  
L. Poovazhgan ◽  
P. Saravanamuthukumar ◽  
S. Javed Syed Ibrahim ◽  
S. Santosh
Keyword(s):  
Particle Size ◽  
Boron Carbide ◽  
Process Parameters ◽  
Positive Impact ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Weight Ratio ◽  
High Strength ◽  
High Wear Resistance ◽  
Particle Size Reduction

Aluminium reinforced with SiC, Al2O3 and B4C etc. possesses an attractive combination of properties such as high wear resistance, high strength to weight ratio and high specific stiffness. Among the various reinforced materials used for aluminium, B4C has outperformed all others in terms of hardening effect. Particle size reduction of B4C is found to have positive impact on the material hardness. In the view of physical properties, B4C has less density than that of SiC and Al2O3, which makes it an attractive reinforcement for aluminium and its alloys for light weight applications. In this work, Al nano B4C composite prepared by ultrasonic cavitation method was machined by Abrasive assisted electrochemical machining using cylindrical copper tool electrodes with SiC abrasive medium. In this paper, attempts have been made to model and optimize process parameters in Abrasive assisted Electro-Chemical Machining of Aluminium-Boron carbide nano composite. Optimization of process parameters is based on the statistical techniques using Response Surface Methodology with four independent input parameters such as voltage, current, abrasive concentration and feed rate were used to assess the process performance in terms of material removal rate and surface finish. The obtained results were compared with abrasive assisted electro chemical machining of Aluminium-Boron carbide micro composite and the effect of particle size on the process parameters was analyzed.

Micro Warm Coining of Stainless Steel Sheets Using Electric Conductive Heating

2011 ◽  
Vol 473 ◽  
pp. 991-998 ◽  
Author(s):  
Kun Ning Zhao ◽  
Burkhard Wietbrock ◽  
Gerhard Hirt
Keyword(s):  
Stainless Steel ◽  
Mechanical Model ◽  
High Strength ◽  
Surface Structures ◽  
Austenitic Steels ◽  
Finite Element Code ◽  
Functional Surface ◽  
Conductive Heating ◽  
Steel Sheets ◽  
Punch Velocity

The motivation of this study is to investigate micro warm coining of metals with high strength (e.g. austenitic steels) in the field of fabricating micro functional surface structures. The current micro cold coining technology, which uses punches made out of steel, is limited to soft metals, such as Al and Cu. Conducting micro cold coining on steels, leads to high tool wear and bad form filling. The approach of this study is integrating electric conductive heating into a micro coining system to realize micro warm coining of stainless steel. This paper presents the experimental and numerical analysis of micro warm coining technology using the material stainless steel 1.4401. A coupled thermal-mechanical model in the commercial Finite-Element-code ABAQUS is used to help analyzing the micro warm coining process. The results are summarized as follows: (1) Open die micro warm coining has been realized. The form filling achieved was 56%, which was three times larger than the form filling of cold micro coining on the same material. (2) Both the experiments and simulations showed that faster processing, by increasing the punch velocity, resulted in a slightly improved form filling (5% from 5 mm/s to 100 mm/s). (3) Surface chilling hindered the filling of thin ribs.

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