Study of Electrochemical Jet Machining Process

1996 ◽  
Vol 118 (4) ◽  
pp. 490-498 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
R. Balkrishna
Keyword(s):  
Turbine Blades ◽  
Electrochemical Machining ◽  
Small Diameter ◽  
Machining Process ◽  
Workpiece Material ◽  
Precise Control ◽  
Machining Rate ◽  
Jet Electrochemical Machining ◽  
The Relationship ◽  
Electrolyte Jet

Jet Electrochemical Machining (ECJM) employs a jet of electrolyte for anodic dissolution of workpiece material. ECJM is extensively used for drilling small cooling holes in aircraft turbine blades and for producing maskless patterns for microelectronics parts. ECJM process drills small diameter holes and complex shape holes without the use of a profile electrode. One of the most significant problems facing ECJM user industries is the precise control of the process. A theoretical analysis of the process and a corresponding model are required for the development of an appropriate control system. This paper presents a mathematical model for determining the relationship between the machining rate and working conditions (electrolyte jet flow velocity, jet length, electrolyte properties, and voltage) of ECJM. This model describes a distribution of electric field and the effect of change of conductivity of electrolyte (caused by heating) on the process performance. A maximum dissolution rate is determined from the allowable increase of electrolyte temperature. Experimental verification of theoretical results is also presented.

scholarly journals Impact of Different Electrolytes on the Machining Rate in ECM Process

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
K. G. Saravanan ◽  
R. Prabu ◽  
A. R. Venkataramanan ◽  
Eden Tekle Beyessa
Keyword(s):  
Metal Removal ◽  
Electrochemical Machining ◽  
Tool Material ◽  
Electrochemical Process ◽  
Machining Process ◽  
Complexing Agents ◽  
Workpiece Material ◽  
Electrolysis Process ◽  
Machining Rate ◽  
The Impact

Electrochemical machining is a nonconventional machining process in which the metal removal is achieved by the electricity and chemical solution known as an electrolyte. It is the reverse electrolysis process where the application of electricity facilitates the current travel in between anode and cathode. The mechanism of the ion movement is similar to the electrolysis process. Electrochemical machining (ECM) is a type of advanced machining process which employs electricity to perform the machining process on the workpiece. It is also known as a reverse electroplating process where metal removal is achieved instead of metal deposition on the metal surface. There are various parameters that affect the metal removal process in the ECM process, such as electrolyte, power supply, workpiece material, and tool material. The electrolyte is one of the key factors impacting the machining rate, surface finish, and reliability of the produced parts. In this project, a brief study is carried out regarding the electrochemical process and the electrolytes where the properties, functions, merits, and demerits are evaluated. The impact of the various electrolytes and their suitability for machining of various metals is also discussed. The findings of the effect produced by using the mixture of the electrolyte in the electrochemical machining process are discussed in this project. The effects of the complexing agents on the electrolyte and the electrochemical process as a whole are also reviewed.

scholarly journals 2D Electrochemical Airfoil Machining Process Model

1995 ◽  
Author(s):  
H. A. Nied ◽  
M. S. Lamphere
Keyword(s):  
Process Model ◽  
Complex Geometry ◽  
Shape Change ◽  
Electrochemical Machining ◽  
Aircraft Engine ◽  
Machining Process ◽  
Field Equations ◽  
Workpiece Material ◽  
Faraday’S Law ◽  
Numerical Predictions

A 2D Electro-Chemical Machining (ECM) process model was developed to aid with tooling design and process optimization by simulation of the ECM process. The boundary element method (BEM) was used to numerically solve the field equations of the process model. The electrochemical anodic reaction was furnished by Faraday’s Law, which provided the relationship for the rate of dissolution at the surface of the workpiece as a function of charge transfer. Accordingly, the workpiece shape change and mass of metal removed by the machining process can be determined as a function of time. The process model includes a library of workpiece material and electrolyte combinations for predicting the electrochemical machining behavior, e.g., titanium alloy 6Al-4V and NaCl electrolytes. These metal/electrolyte combinations are of special interest in the aircraft engine industry for manufacturing heat-resistant, rotary components with complex geometry such as airfoil blades. The major features of the numerical computer program are briefly described with a selected example of machining a typical fan blade. Preliminary comparison of the numerical predictions with the nominal airfoil geometry showed good agreement and is discussed below.

Experimental study of an electrostatic field–induced electrolyte jet electrical discharge machining process

2015 ◽  
Vol 231 (10) ◽  
pp. 1752-1759 ◽  
Author(s):  
Zhang Yaou ◽  
Han Ning ◽  
Kang Xiaoming ◽  
Zhao Wansheng ◽  
Xu Kaixian
Keyword(s):  
Electrostatic Field ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Cyclic Process ◽  
Tool Electrode ◽  
Series Of Experiments ◽  
Current Detection ◽  
Electrolyte Jet

In this study, a new electrostatic field–induced electrolyte jet electrical discharge machining method has been proposed, which can automatically generate the tool electrode. Then, a series of experiments have been carried out to reveal the machining mechanism and test the machining ability of this method. The continuous observation experiments and the online current detection experiments have demonstrated that the electrolyte jet discharge machining is a pulsing, dynamic and cyclic process. Moreover, the 20-min time long reverse polarity experiments on the silicon surface have revealed that the machining is an electrical discharge machining process during the negative polarity machining; however, in the positive polarity machining, it is a hybrid electrical discharge machining and electrochemical machining process. Furthermore, the craters as small as 2 µm in diameter on stainless steel and silicon are produced by this electrolyte jet electrical discharge machining, which has proved the micro-machining ability of this method.

The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3583-3586 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Three Dimension ◽  
Cathode Design ◽  
Aero Engine ◽  
Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

Optimization of Turbine Blade’s Cathodes Feeding Routes in Three-Electrode Feeding Electrochemical Machining

2011 ◽  
Vol 201-203 ◽  
pp. 2737-2740
Author(s):  
Lei Wang
Keyword(s):  
Current Efficiency ◽  
Turbine Blades ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Shape Evolution ◽  
Feeding Method ◽  
Factors Influencing ◽  
Improve Accuracy

To improve accuracy of turbine blades by electrochemical machining (ECM), a new cathode’s feeding method was studied. The rational optimization rules were proposed. Based on the theory of ECM, the blade’s shape evolution was analysed. The influence of the current efficiency brought by the passivating electrolyte, and flow factors influencing the machining process were also considered. According to the rules the cathode’s feeding route was optimized. By using the three-electrode feeding ECM machine, the cathode’s feeding routes can be varied flexibly.

Primary Research on Jet ECM Processing of Difficult to Cut Materials

2013 ◽  
Vol 554-557 ◽  
pp. 1793-1799 ◽  
Author(s):  
Piotr Lipiec ◽  
Dominik Wyszynski ◽  
Sebastian Skoczypiec
Keyword(s):  
Current Density ◽  
Large Scale ◽  
Electrochemical Machining ◽  
Current Density Distribution ◽  
Electrochemical Process ◽  
Experiment Planning ◽  
Work Piece ◽  
Machined Surface ◽  
Jet Electrochemical Machining ◽  
Electrolyte Jet

Unconventional production techniques became interesting and promising part of manufacturing methods. They provide complementary, to traditional loss methods, solutions enabling use of high - performance engineering materials for construction of machinery and industrial equipment. By using properly selected methods or their hybrids difficult to cut materials as steel, alloys, sintered materials and composites can be processed. Among the wide variety of unconventional methods of materials forming, particular attention should be given to electrochemical machining, which has been successfully used in various industries. This fact proves attractiveness and versatility of ECM. The method could be used on large scale and many variations was developed as each application requires an individual approach and has own requirements. One of the least known and described type of electrochemical machining is jet ECM where the electrolyte jet stream acts as a tool. In this kind of machining, the part is shaped only in the area where the electrolyte jet strikes the surface. This is due to the fact that the current density distribution is located just below the stream. In the area around the jet hitting the work piece thin electrolyte layer is formed. Thickness of that layer is growing rapidly. Since the electrolyte jet machining is an electrochemical process, the machined surface has all the benefits of ECM. There is no burrs and low temperature of the process prevents appearance of cracks and there is no heat-affected zone. Electrolyte jet machining can be used as well as in macro and micro drilling, turning, texturing, and electroplating. The process can be controlled by proper selection of such parameters as time, the current density and the diameter of the jet. Jet ECM can be used not only for material removal, but also for coloration (passivation) by means of anodic dissolution. 3D shaping of elements is also possible by controlling the current and the velocity of the electrolyte stream. In addition, by changing the polarity of the applied voltage it is possible to use this method in broadly considered electroplating. The paper presents results of the initial research on jet electrochemical machining (jet ECM) of acid proof steel and tungsten carbide. The material processing was carried in two ways – drilling holes and shaping grooves. Shaping was realized in milling and face turning regime. The influence of the two basic process parameters voltage and pressure was examined. In order to get rough information about the jet ECM process experiment planning method was applied. Obtained results enable planning of the further extended research.

scholarly journals Fast Fabrication of Complex Surficial Micro-Features Using Sequential Lithography and Jet Electrochemical Machining

Micromachines ◽  
2020 ◽  
Vol 11 (10) ◽  
pp. 948
Author(s):  
Ming Wu ◽  
Krishna Kumar Saxena ◽  
Zhongning Guo ◽  
Jun Qian ◽  
Dominiek Reynaerts
Keyword(s):  
Contact Process ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Shape Error ◽  
Shape Deviation ◽  
Shape Accuracy ◽  
High Productivity ◽  
Micro Features ◽  
Surface Microstructures ◽  
Jet Electrochemical Machining

This paper presents fabrication of complex surficial micro-features employing a cross-innovative hybrid process inspired from lithography and Jet-ECM. The process is referred here as mask electrolyte jet machining (MEJM). MEJM is a non-contact machining process which combines high resolution of lithography and greater flexibility of Jet-ECM. It is a non-contact process which can fabricate variety of microstructures on difficult-to-machine materials without need of expensive tooling. The presented work demonstrates the process performance of this technology by statistical analysis and multivariate kernel density estimation (KDE) based on probabilistic density function. Micro-letters are fabricated as an example of complex surficial structure comprising of multiple intersecting, straight and curved grooves. The processing response is characterized in terms of geometrical size, similarity ratio, and cumulative shape deviation. Experimental results demonstrated that micro letters with good repeatability (minimum SD of shape error ratio 0.297%) and shape accuracy (minimum shape error of 0.039%) can be fabricated with this technology. The results suggest MEJM could be a promising technology for batch manufacturing of surface microstructures with high productivity.

scholarly journals The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 404 ◽  
Author(s):  
Xinmin Zhang ◽  
Xudong Song ◽  
Pingmei Ming ◽  
Xinchao Li ◽  
Yongbin Zeng ◽  
...  
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Horizontal Orientation ◽  
Jet Electrochemical Machining ◽  
Machining Characteristics ◽  
Machining Localization ◽  
Vertical Jet

Jet electrochemical machining (Jet-ECM) is a significant prospective electrochemical machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet machining, and the effect of jet orientations on machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of machining localization and a reduction of MMR for horizontal jet electrochemical machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve machining accuracy.

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