Identification of Interelectrode Gap Sizes in Pulse Electrochemical Machining

1997 ◽  
Vol 144 (11) ◽  
pp. 3913-3919 ◽  
Author(s):  
B. Wei ◽  
K. P. Rajurkar ◽  
S. Talpallikar
Keyword(s):  
Electrochemical Machining ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap

Modelling and Analysis of Pulse Electrochemical Machining (PECM)

1994 ◽  
Vol 116 (3) ◽  
pp. 316-323 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
B. Wei
Keyword(s):  
Anodic Dissolution ◽  
Experimental Studies ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Tool Design ◽  
Machining Parameters ◽  
Electrolyte Flow ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap ◽  
Continuous Current

A small interelectrode gap in Electrochemical Machining (ECM) results in improved dimensional accuracy control and simplified tool design. However, using a small gap with conventional ECM equipment adversely affects the electrolyte flow or mass transport conditions in the gap, leading to process instability. The most remarkable breakthrough in this regard is the development of ECM using pulsed current. Pulse Electrochemical Machining (PECM) involves the application of a voltage pulse at high current density in the anodic dissolution process. PECM allows for more precise monitoring and control of machining parameters than ECM using continuous current. Small interelectrode gap, low electrolyte flow rate, gap state recovery during the pulse-off times and improved anodic dissolution efficiency features encountered in PECM lead to improved workpiece precision and surface finish when compared with ECM using continuous current. This paper presents mathematical models for the PECM process which take into consideration the nonsteady physical phenomena in the gap between the electrodes, including the conjugate fields of electrolyte flow velocities, pressure, temperature, gas concentrations, current densities and anodic material removal rates. The principles underlying higher dimensional accuracy and simpler tool design attainable with optimum pulse parameters are also discussed. Experimental studies indicate the validity of the proposed PECM models.

Modelling and Monitoring Interelectrode Gap in Pulse Electrochemical Machining

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 177-180 ◽  
Author(s):  
K.P. Rajurkar ◽  
B. Wei ◽  
J. Kozak ◽  
J.A. McGeough
Keyword(s):  
Electrochemical Machining ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap

Pressure Generated During Pulse Electrochemical Machining

2001 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar
Keyword(s):  
High Speed ◽  
Turbine Blades ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap ◽  
Complex Shapes ◽  
High Speed Data Acquisition ◽  
High Speed Data

Abstract Pulse electrochemical machining (PECM) provides an economical and effective method for machining high strength, heat-resistant materials into complex shapes such as turbine blades of titanium alloys. The dimensional accuracy of PECM can be improved if a small interelectrode gap is maintained. This paper presents an interelectrode gap model for estimating pulse pressure generated after pulse current switched on, and the subsequent dynamic loading on the electrodes during PECM. A specially built PECM cell and a high-speed data acquisition system are used to measurement of wave pressure for verification of estimated values.

Precise pulse electrochemical machining by bipolar current

2004 ◽  
Vol 149 (1-3) ◽  
pp. 419-425 ◽  
Author(s):  
A. Zaytsev ◽  
I. Agafonov ◽  
N. Gimaev ◽  
R. Moukhoutdinov ◽  
A. Belogorsky
Keyword(s):  
Electrochemical Machining ◽  
Pulse Electrochemical Machining

Study of Pulse Electrochemical Machining Performance of Deep-Small Hole on Nickel-Based Alloy

2011 ◽  
Vol 204-210 ◽  
pp. 1830-1834
Author(s):  
Zhao Long Li ◽  
Shi Chun Di
Keyword(s):  
Base Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Math Model ◽  
Technical Parameters ◽  
Pulse Electrochemical Machining ◽  
Small Holes

The method of machining deep hole on Ni-base alloy which can tolerant high temperature by pulse electrochemical machining has been proposed in this paper. Five technical parameters are discussed on the effect of mass removal rate of machining process. Establish a dynamic math model, and analyze the effect of process parameters on the mass material removal rate of deep small holes. Machining accuracy of deep small holes was analyzed.

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