scholarly journals Research on Stagger Coupling Mode of Pulse Duration and Tool Vibration in Electrochemical Machining

2018 ◽  
Vol 8 (8) ◽  
pp. 1296 ◽  
Author(s):  
Xiaochen Jiang ◽  
Jia Liu ◽  
Di Zhu ◽  
Mingming Wang ◽  
Ningsong Qu
Keyword(s):  
Pulse Duration ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Tool Vibration ◽  
Coupling Mode ◽  
Machining Localization ◽  
Electrolysis Products ◽  
Gas Void Fraction

Tuning the coupling of pulse duration and tool vibration in electrochemical machining (PVECM) is an effective method to improve machining accuracy and surface quality. In general, the pulse is set at the same frequency as the tool vibration, and a symmetrical distribution is attained at the minimum inter-electrode gap. To analyse the characteristics of the electrolyte fluid flow and of the electrolysis products in the oscillating inter-electrode gap, a dynamic simulation of the PVECM process was carried out. The simulation results indicated that the electrolyte pressure and gas void fraction when the pulse arrived as the inter-electrode gap was narrowing clearly differed from those when the inter-electrode gap was expanding. Therefore, in addition to the traditional symmetry coupling mode, two other coupling modes called the pre-position and the post-position coupling modes are proposed which use a pulse either just before or just after the minimum inter-electrode gap. Comparative experiments involving the feed rate and machining localization were carried out to evaluate the influence of the three coupling modes. In addition, current waveforms were recorded to analyse the differences between the three coupling modes. The results revealed that the highest feed rate and the best machining localization were achieved by using the pre-position coupling mode.

Fabrication of Micro Structures by Ultra Short Voltage Pulse Electrochemical Machining

2009 ◽  
Vol 419-420 ◽  
pp. 813-816 ◽  
Author(s):  
Hui Chen ◽  
Zhen Long Wang ◽  
Zi Long Peng ◽  
Wan Sheng Zhao
Keyword(s):  
Voltage Pulse ◽  
Electrochemical Machining ◽  
Pulse Frequency ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Stray Current ◽  
Micro Fabrication ◽  
Micro Hole ◽  
Micro Structures ◽  
Machining Localization

. The purpose of this paper is to study the application of electrochemical machining (ECM) technology for the fabrication of micro structures. The stray current corrosion, i.e. machining localization is a critical obstacle to micro fabrication for ECM. To machine micro structures by electrochemical machining ultra short voltage pulse is used. The effects of electrochemical machining parameters such as voltage, pulse duration, pulse frequency, and electrolyte composition on the machining accuracy were studied. In experiments, a micro hole was machined on stainless steel with cylindrical and square electrodes to investigate these effects.

Experiment Study on Micro-Seam in Electrochemical Machining

2013 ◽  
Vol 584 ◽  
pp. 15-19
Author(s):  
Zhi Yong Li ◽  
Pei Yu Dong ◽  
Yi Gang Wang
Keyword(s):  
Applied Voltage ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Micro Machining ◽  
Wire Electrode ◽  
Process Stability ◽  
Electrode Shape ◽  
The Wire ◽  
Better Than

In this study, we firstly developed a numerical electrochemical micro-machining (EMM) setup. Furthermore, the effects of five vital process parameters, applied voltage, electrolyte type, electrode shape and diameter, electrode feed rate on micro-seams machining accuracy and process stability were evaluated. The experimental results show that: Wire electrodes machining accuracy is higher than that of sheet electrode. With the wire electrodes diameter decreased from 0.2mm to 0.06mm, micro-seam width is reduced by 36.55%. With the wire electrode feed rate increased from 0.2mm/min to 0.6mmm/min, micro-seam width is reduced by 44.2%. Sheet electrodes machining stability is better than that of wire electrode. The number of machining stability of sheet electrode is 25% higher than that of wire electrode in the condition of 8V applied voltage.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

Fundamental Experimental Study on Numerical-Control Electrochemical Finish Machining for Integral Impeller Blade

2011 ◽  
Vol 55-57 ◽  
pp. 1275-1280 ◽  
Author(s):  
Jian Min Wu ◽  
Jia Wen Xu
Keyword(s):  
Electrochemical Machining ◽  
Normal Direction ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Blade Surface ◽  
Electrode Gap ◽  
Impeller Blade ◽  
Finish Machining

While the surface of integral impeller blade was electrochemically machined, cathode cannot rotate in accordance with other movement axes, which results in nonuniformity in velocity of electrolyte and normal direction of the machining blade surface, thereby causing inaccuracy in the machined blade surface. In order to solve this problem, the shaping law was studied in Electrochemical Finish Machining. Then relative positions between cathode slot and blade surface were analyzed during the process of Electrochemical Machining (ECM). Three parameters, namely feed direction, feed velocity and initial machining inter-electrode gap, were adjusted to conduct the fundamental experiments when direction of cathode slot was changed. Afterwards machining accuracy as well as surface quality of workpiece was analyzed. Finally according to experimental results, direction of cathode slot was determined practically in electrochemical machining process and the integral impeller blades meeting the requirement were electrochemically machined.

Electrochemical Machining of Micro-Structures With Nanosecond Pulses

2007 ◽  
Author(s):  
Zhaoyang Zhang ◽  
Di Zhu ◽  
Ningsong Qu ◽  
Kun Wang
Keyword(s):  
Pulse Duration ◽  
Electrochemical Machining ◽  
Experimental System ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Voltage Amplitude ◽  
Nanosecond Pulses ◽  
Micro Ecm ◽  
Micro Tool ◽  
Micro Structures

Electrochemical machining (ECM) is considered an advanced and promising technique due to several special advantages, such as non-contact machining without cutting force, no tool wear and heat-affected layer, etc. Base on the experimental results of micro-ECM, the influence of predominant process parameters, i.e. electrolyte concentration, pulse duration, period and voltage amplitude of power supply, on machining accuracy were investigated and discussed. Experimental showed that lower voltage amplitude and shorter pulse duration in micro-ECM process could produce more accurate micro structure shape. Using the self-developed experimental system, the micro tool-electrode and the complex micro-structures were sequentially machined. Upon the application of ultrashort voltage pulses, the letters with 20μm in line width were fabricated stably by the W tool electrode with 10μm diameter.

Process Simulation of Electrochemical Machining of Convexity Structure on Revolving Workpiece

2015 ◽  
Author(s):  
Zengwei Zhu ◽  
Dengyong Wang ◽  
Jun Bao ◽  
Di Zhu
Keyword(s):  
Mathematical Model ◽  
Process Simulation ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Relative Rotation ◽  
Electrode Gap ◽  
Simulation Results

A special electrochemical machining (ECM) process using a revolving cathode tool with hollow windows is presented. Unlike conventional sinking ECM, this presented ECM process fabricates the convexity structures on a revolving part by the relative rotation of anode workpiece and cathode tool. In this paper, a mathematical model is established to describe the evolution of the machining process, the finite element simulations of the new forming fashion are focused for the workpiece’s revolving surface and the convexity’s side profile. The simulation results show that both the cathode feed rate and the applied voltage have significant influence on the equilibrium inter-electrode gap and the material removal rate. The side profile of the convexity is related to radius of the cathode tool. It is expected that the equilibrium gap and steady removal rate could be achieved by optimizing the cathode feed rate and the voltage, the required side profile taper of the convexity could be obtained by selecting the proper tool radius.

Improvement of leading-edge accuracy by optimizing the cathode design plane in electrochemical machining of a twisted blade

2019 ◽  
Vol 234 (4) ◽  
pp. 814-824 ◽  
Author(s):  
Lingguo Yu ◽  
Dong Zhu ◽  
Yujun Yang ◽  
Jibin Zhao
Keyword(s):  
Three Dimensional ◽  
Electrochemical Machining ◽  
Leading Edge ◽  
The Body ◽  
Machining Process ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Cathode Design ◽  
Twisted Blade ◽  
Blade Leading Edge

Cathode design plays an important role in the electrochemical machining of aero engine blades and is a core issue influencing machining accuracy. Precision electrochemical machining of the leading edge of a twisted blade is particularly difficult. To improve the electrochemical machining accuracy of the leading edge, this article deals with cathode design by optimizing the design plane based on the three-dimensional potential distribution in the inter-electrode gap. A mathematical model is established according to the electrochemical machining shaping law, and the formation of the blade leading edge is simulated using ANSYS. The simulation results show that the blade leading-edge profile obtained with the optimized planar cathode is more consistent with the blade model profile. The optimized planar cathode and a non-optimized planar cathode are designed and a series of corresponding electrochemical machining experiments is carried out. The experiments show that the electrochemical machining process is stable and that the surface quality near the leading edge of the samples is slightly better than that of the body surface. Compared with the non-optimized planar cathode, the allowance difference at the leading-edge vertex is decreased by 0.062 mm. Using the optimized planar cathode allows fabrication of a workpiece whose shape is similar to that of the designed twisted blade.

scholarly journals The effects of the process parameters in electrochemical machining on the surface quality

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Nguyen Thi Bich Nhung ◽  
Dao Thanh Liem ◽  
Truong Quoc Thanh
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Electrode Gap

Based on the number of previous studies, this study aims to investigate the effects of process parameters of an Electrochemical Machining process, which are electrolyte concentration, the voltage applied to the machine, feed rate of the electrode, and Inter-Electrode Gap between tool and workpiece. Aluminum samples of 25 mm diameter x 25 mm height and 30mm diameter x 25mm height of the tool is made up of copper with a circular cross-section with 2 mm internal hole. The design of the system is based on the Taguchi method. Here, the signal-to-noise (S/N) model, the analysis of variance (ANOVA) and regression analyses are applied to determine optimal levels and to investigate the effects of these parameters on surface quality. Finally, the experiments that use the optimal levels of machining parameters are conducted to verify the effects of the process parameters on the surface quality of the products. The results pointed out a set of optimal parameters of the ECM process. The Inter-Electrode Gap between the tool and workpiece has extremely effected on these Material Removal rates and surface roughness. The Material Removal Rate increases with diseases in Inter-Electrode Gap, and Ra diseases with diseases in Inter-Electrode Gap. The experimental results show that maximum Material Removal Rate has obtained with electrolyte concentration at 100 g/l, feed rate at 0.0375 mm/min, the voltage at 15V, and Inter-Electrode Gap at 0.5mm. The minimum Ra has obtained with electrolyte concentration at 80 g/l, feed rate at 0.0468 mm/min, the voltage at 10V, and Inter-Electrode Gap at 0.5mm. This result has led to need studies on these parameters in Electrochemical Machining, which are improving productivities and surface roughness of the products.   

Influence of Magnetic Field Distribution on ECM Process

2007 ◽  
Vol 339 ◽  
pp. 50-58 ◽  
Author(s):  
Bao Ji Ma ◽  
Zhi Jian Fan ◽  
D.J. Stephenson
Keyword(s):  
Magnetic Field ◽  
Finite Element ◽  
Permanent Magnet ◽  
Electrochemical Machining ◽  
Process Efficiency ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Element Analysis ◽  
Magnet Design ◽  
The Magnetic Field

Based on the concept of the interaction between a magnetic and electric field, a magnetic field was suppressed on the Electrochemical Machining (ECM) setup to improve the copying accuracy of ECM. Mathematical modeling and finite element modeling of the magnetic field was also developed using ANSYS to study the influence of permanent magnet design on the ECM process. The results indicate that by introducing the magnetic field the threshold of electrochemical reaction is decreased and the tracks of ions become complicated which makes the chemical reaction more extensive and more uniform in the inter-electrode gap. The distribution of magnetic field in the gap helps to improve the machining accuracy and the process efficiency, when the permanent magnet is at the end of the electrodes. Experiments have been carried out to validate the results of finite element analysis and the effect of a magnetic field on the ECM process is discussed.

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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