Electrochemical Machining Recycling for Metal Recovery and Waste Elimination

2014 ◽  
Author(s):  
Brian Skinn ◽  
Savidra Lucatero ◽  
Timothy Hall ◽  
Stephen Snyder ◽  
E. Jennings Taylor ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Material Properties ◽  
High Surface ◽  
Electrochemical Machining ◽  
Value Added ◽  
Workpiece Material ◽  
Mass Removal ◽  
Integrated Technology ◽  
Low Mass ◽  
Conventional Machining

This paper will discuss an integrated technology being developed by Faraday to recover and recycle metals from electrochemical machining (ECM) electrolytes. ECM is suited for low mass removal, high value-added manufacturing steps that cannot be easily performed using conventional machining, whether due to workpiece material properties, tooling limitations, or high surface integrity requirements. Sludge byproducts formed during conventional ECM processes are difficult and expensive to recycle, and discarding the sludge results in the loss of potentially valuable “waste” metal as well as entrained electrolyte. The FARADAYIC® Recycling ECM [(R) ECM] technology machines metals into the electrolyte to a concentration of 800–1500 ppm (mg L−1), and subsequently recovers those metals by electrowinning in solid/metallic form devoid of hydroxides/hydrated oxides, without intermediate electrolyte processing.

The investigation on processes of forming the parts surface layer have made of non-ferrous metals and their alloys by complex methods

2020 ◽  
pp. 66-71
Author(s):  
V.E. Inozemtsev ◽  
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Electrochemical Machining ◽  
Aluminum Bronze ◽  
Workpiece Material ◽  
Surface Microrelief ◽  
Ductile Metals ◽  
High Surface Quality ◽  
Common Effect ◽  
Processing Modes

The study had provided shows the characteristics of the some surfaces obtained with the electrochemical mechanical processing and describes the common effect of processing modes and its conditions on the surface microrelief. This shaping method is taking an efficiency on finishing operations, which are required both in traditional ways of processing by subtracting the workpiece material, and in an additive technologies. One of the main advantages of an electrochemical machining is the ability at achieving high surface quality and the absence of impacts on the lower layers of the workpiece's surface. The results of surface studies are considered with an example of aluminum, bronze-graphite, iron-graphite, and recommendations are given for improving the surface quality of ductile metal based parts including the materials of the tool blade and its characteristics. The study has focused on the turning, milling and abrasive machining. The greatest relevance of the application of this processing method is associated with the impossibility of obtaining accurate geometric parameters of parts by the most widely used shaping methods at the present, especially for processing parts made of ductile metals and its alloys.

Experimental Investigation into Surface Integrity Finished by Abrasive Jet with Grinding Wheel as Restraint

2007 ◽  
Vol 359-360 ◽  
pp. 244-248 ◽  
Author(s):  
Chang He Li ◽  
Shi Chao Xiu ◽  
Guang Qi Cai
Keyword(s):  
Residual Stresses ◽  
Surface Integrity ◽  
High Surface ◽  
Surface Hardness ◽  
Ground Surface ◽  
Grinding Wheel ◽  
Workpiece Material ◽  
Machined Surface ◽  
X Ray ◽  
Finished Surface

The surface integrity finished by abrasive jet with grinding wheel as restraint was experimentally investigated. Experiments were performed with plane grinder M7120 equiped with abrasive jet finishing device and harded workpiece material 45 steel which was ground with the surface roughness values of Ra=0.6μm.The machined surface morphology was studied using Scanning Electron Microscope (SEM) and microscope and microcosmic geometry parameters were measured with TALYSURF5 instrument. The surface hardness for ground and finished surface was measured with HVS-1000 instrument and the phase structure was analyzed by X-ray energy dispersive spectram and residual stresses were measured by PW3208 X-ray diffraction. The Results show that longitudinal geometry parameter values were diminished and ripple was obviously improved comparing with ground surface. Furthermore, the finished surface has condensible residual stresses and high surface hardness comparability compared to grinding machining surface. As a result, life and precision consistency of finished workpiece were improved.

scholarly journals Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

2021 ◽  
Author(s):  
Lukas Seeholzer ◽  
Stefan Süssmaier ◽  
Fabian Kneubühler ◽  
Konrad Wegener
Keyword(s):  
Surface Quality ◽  
Influencing Factors ◽  
Material Properties ◽  
High Surface ◽  
Workpiece Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Surface Temperatures ◽  
Process Forces ◽  
The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

scholarly journals Multi-stable composite twisting structure for morphing applications

2012 ◽  
Vol 468 (2141) ◽  
pp. 1230-1251 ◽  
Author(s):  
X. Lachenal ◽  
P. M. Weaver ◽  
S. Daynes
Keyword(s):  
Analytical Model ◽  
Material Properties ◽  
Degrees Of Freedom ◽  
Design Parameters ◽  
Engineering Structures ◽  
The Past ◽  
Wide Range ◽  
Morphing Structure ◽  
Low Mass ◽  
Unstable States

Conventional shape-changing engineering structures use discrete parts articulated around a number of linkages. Each part carries the loads, and the articulations provide the degrees of freedom of the system, leading to heavy and complex mechanisms. Consequently, there has been increased interest in morphing structures over the past decade owing to their potential to combine the conflicting requirements of strength, flexibility and low mass. This article presents a novel type of morphing structure capable of large deformations, simply consisting of two pre-stressed flanges joined to introduce two stable configurations. The bistability is analysed through a simple analytical model, predicting the positions of the stable and unstable states for different design parameters and material properties. Good correlation is found between experimental results, finite-element modelling and predictions from the analytical model for one particular example. A wide range of design parameters and material properties is also analytically investigated, yielding a remarkable structure with zero stiffness along the twisting axis.

Surface and Sub-Surface Integrity of Ultra- Machined BK7 Using Fine and Coarse Grained Diamond Wheels

2007 ◽  
Vol 359-360 ◽  
pp. 234-238 ◽  
Author(s):  
Qing Liang Zhao ◽  
Bo Wang ◽  
Ekkard Brinksmeier ◽  
Otmann Riemer ◽  
Kai Rickens ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
High Surface ◽  
Coarse Grained ◽  
Nanometer Scale ◽  
Grinding Wheels ◽  
Fine Grained ◽  
Optical Glasses ◽  
Diamond Grinding ◽  
Surface Damages

This paper aims to evaluate the surface and sub-surface integrity of optical glasses which were correspondingly machined by coarse and fine-grained diamond grinding wheels on Tetraform ‘C’ and Nanotech 500FG. The experimental results show that coarse-grained diamond grinding wheels are capable of ductile grinding of optical glasses with high surface and sub-surface integrity. The surface roughness values are all in nanometer scale and the sub-surface damages are around several micros in depth, which is comparative to those machined by fine-grained diamond wheels.

An Expert System Based on a Hybrid Multi-Criteria Decision Making Method for Selection of Non-Conventional Machining Processes

2015 ◽  
Vol 735 ◽  
pp. 41-49 ◽  
Author(s):  
Arash Azaryoon ◽  
Musa Hamidon ◽  
Ashraf Radwan
Keyword(s):  
Decision Making ◽  
Analytic Network Process ◽  
Reference Points ◽  
Multi Criteria Decision Making ◽  
Compromise Solution ◽  
Machining Processes ◽  
Workpiece Material ◽  
Topsis Technique ◽  
Conventional Machining ◽  
Selection Of

In this study, a knowledge-based system has been developed for selection of non-conventional machining processes using a hybrid multi-criteria decision making Method. This approach is a combination ofDEMATEL(Decision Making Trial and Evaluation Laboratory),ANP(Analytic Network Process) andVIKOR(VlseKriterijumska Optimizacija I Kompromisno Resenje, in Serbian, meaning Multi-criteria Optimization and Compromise Solution) methods which evaluates different types of quantitative and qualitative measures of performance and economic factors, and ultimately provides a set of capable processes in order of priority. Twelve machining processes, eight group of workpiece material and eighteen shape features have been investigated in this study. What separates this approach from others is that, this hybrid method considers the influence of factors in the network relation map as well as their relative importance. Moreover, unlike other popular ranking methods such as TOPSIS (Technique for Order Preference by Similarity to the Ideal Solution), it is not just based on two reference points, namely ideal and inferior points; instead, it proposes a compromise solution and not just a single ranking score. Observations have shown that the developed system works satisfactorily, yields acceptable results and makes accurate decisions as well. It also provides a comparative study among the alternative processes by utilizing graphical features for better analysis and judgment of acceptable alternatives.

scholarly journals Enhancement of Photocatalytic Oxidation of Glucose to Value-Added Chemicals on TiO2 Photocatalysts by A Zeolite (Type Y) Support and Metal Loading

Catalysts ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 423 ◽  
Author(s):  
Kamonchanok Roongraung ◽  
Surawut Chuangchote ◽  
Navadol Laosiripojana
Keyword(s):  
Formic Acid ◽  
Surface Area ◽  
Gluconic Acid ◽  
Photocatalytic Oxidation ◽  
High Surface ◽  
Sol Gel ◽  
High Surface Area ◽  
Value Added ◽  
Incipient Wetness Impregnation ◽  
Microwave Assisted

TiO2-based photocatalysts synthesized by the microwave-assisted sol-gel method was tested in the photocatalytic glucose conversion. Modifications of TiO2 with type-Y zeolite (ZeY) and metals (Ag, Cu, and Ag-Cu) were developed for increasing the dispersion of TiO2 nanoparticles and increasing the photocatalytic activity. Effects of the TiO2 dosage to zeolite ratio (i.e., TiO2/ZeY of 10, 20, 40, and 50 mol %) and the silica to alumina ratio in ZeY (i.e., SiO2:Al2O3 of 10, 100, and 500) were firstly studied. It was found that the specific surface area of TiO2/ZeY was 400–590 m2g−1, which was higher than that of pristine TiO2 (34.38 m2g−1). The good properties of 20%TiO2/ZeY photocatalyst, including smaller particles (13.27 nm) and high surface area, could achieve the highest photocatalytic glucose conversion (75%). Yields of gluconic acid, arabinose, xylitol, and formic acid obtained from 20%TiO2/ZeY were 9%, 26%, 4%, and 35%, respectively. For the effect of the silica to alumina ratio, the highest glucose conversion was obtained from SiO2:Al2O3 ratio of 100. Interestingly, it was found that the SiO2:Al2O3 ratio affected the selectivity of carboxylic products (gluconic acid and formic acid). At a low ratio of silica to alumina (SiO2:Al2O3 = 10), higher selectivity of the carboxylic products (gluconic acid = 29% and formic acid = 32%) was obtained (compared with other higher ratios). TiO2/ZeY was further loaded by metals using the microwave-assisted incipient wetness impregnation technique. The highest glucose conversion of 96.9 % was obtained from 1 wt. % Ag-TiO2 (40%)/ZeY. Furthermore, the bimetallic Ag-Cu-loaded TiO2/ZeY presented the highest xylitol yield of 12.93%.

Analysis and Prediction of Surface Integrity in Machining: A Review

2014 ◽  
Vol 610 ◽  
pp. 1002-1020 ◽  
Author(s):  
Yuan Gao ◽  
Xin Huang ◽  
Ming Jie Lin ◽  
Zheng Guo Wang ◽  
Rong Lei Sun
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Material Properties ◽  
Cutting Parameters ◽  
Mechanical Parameters ◽  
Factors Affecting ◽  
Grain Size And Shape

Surface integrity is widely used for evaluating the quality of machined components. It has a set of various parameters which can be grouped as: (a) topography parameters such as surface roughness, textures and waviness (b) mechanical parameters such as residual stresses and hardness, and (c) metallurgical state such as microstructure, phase transformation, grain size and shape, inclusions etc. Surface roughness and residual stresses are among the most significant parameters of surface integrity, so that it is worth investigating them particularly. Many factors affect the surface integrity of machined components, including cutting parameters, tool parameters, material properties and vibrations. We can make prediction and optimization for surface integrity by taking advantage of these factors. This paper reviews previous studies and gives a comprehensive summary of surface integrity in the following order: introduction of surface integrity, main parameters of surface integrity, factors affecting surface integrity, prediction and optimization for surface integrity.

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