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.

A Method for Harvesting Energy Using Piezoelectric Transducers

2015 ◽  
Vol 727-728 ◽  
pp. 607-611 ◽  
Author(s):  
Kshitij Chopra ◽  
Kritika Nigam ◽  
Sujata Pandey
Keyword(s):  
Zinc Oxide ◽  
Simulation Software ◽  
Piezoelectric Transducers ◽  
Comsol Multiphysics ◽  
Ambient Vibrations ◽  
Multiphysics Simulation

This paper analyses the behaviour ofpiezoelectric transducer for harvesting energy. The transducer was designedusing different materials for harnessing energy that include Zinc Oxide, LeadZirconate Titanate (PZT-2) and Quartz. The transducer was simulated using thesematerials and the voltage generated from ambient vibrations was analysed. MEMsmodule of COMSOL Multiphysics Simulation software was used to perform thesimulations. Behaviour of different materials towards various frequencies madeknown in this study gives an opportunity to estimate the fabricated device and alsosheds light on prospective applications it fits.

Multiphysics Design and Analysis Simulations for Power Electronic Device Wirebonds

2003 ◽  
Author(s):  
Patrick W. Wilkerson ◽  
Andrzej J. Przekwas ◽  
Chung-Lung Chen
Keyword(s):  
Heat Dissipation ◽  
Electronic Device ◽  
Electronic Devices ◽  
Thermal Conditions ◽  
Simulation Software ◽  
Operating Conditions ◽  
Power Electronic ◽  
Stress Concentrations ◽  
Multiphysics Simulation ◽  
Multiphysics Simulations

Multiscale multiphysics simulations were performed to analyze wirebonds for power electronic devices. Modern power-electronic devices can be subjected to extreme electrical and thermal conditions. Fully coupled electro-thermo-mechanical simulations were performed utilizing CFDRC’s CFD-ACE+ multiphysics simulation software and scripting capabilities. Use of such integrated multiscale multiphysics simulation and design tools in the design process can cut cost, shorten product development cycle time, and result in optimal designs. The parametrically designed multiscale multiphysics simulations performed allowed for a streamlined parametric analysis of the electrical, thermal, and mechanical effects on the wirebond geometry, bonding sites and power electronic device geometry. Multiscale analysis allowed for full device thermo-mechanical analysis as well as detailed analysis of wirebond structures. The multiscale simulations were parametrically scripted allowing for parametric simulations of the device and wirebond geometry as well as all other simulation variables. Analysis of heat dissipation from heat generated in the power-electronic device and through Joule heating were analyzed. The multiphysics analysis allowed for investigation of the location and magnitude of stress concentrations in the wirebond and device. These stress concentrations are not only investigated for the deformed wirebond itself, but additionally at the wirebond bonding sites and contacts. Changes in the wirebond geometry and bonding geometry, easily changed through the parametrically designed simulation scripts, allows for investigation of various wirebond geometries and operating conditions.

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.

Description of the PM Process by Using Ishikawa-Analysis

2013 ◽  
Vol 752 ◽  
pp. 48-56
Author(s):  
Andrea Simon ◽  
Károly Kovács ◽  
C. Hakan Gür ◽  
Tadeusz Pieczonka ◽  
Zoltán Gácsi
Keyword(s):  
Thermal Conductivity ◽  
Thermal Expansion ◽  
Powder Metallurgy ◽  
Thermal Expansion Coefficient ◽  
Expansion Coefficient ◽  
High Strength ◽  
Manufacturing Technology ◽  
Low Density ◽  
Composite Manufacturing ◽  
Low Thermal Expansion

Composites are special material which can provide individual properties such as high strength with low density or good thermal conductivity with low thermal expansion coefficient. Composites conform to the constantly evolving and more complex expectations. In order to make a product with good quality, it is important to choose suitable materials and technology. In this research powder metallurgy (PM), as one of the most common composite manufacturing technology, was examined -which factors and mechanisms influence mostly the properties of the product. Ishikawa method was used to reveal these correlations.

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.

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