This research aims to understand flushing of by-products in electrochemical machining (ECM) by modeling and experimentally verifying mechanism of particle transport in inter-electrode gap under low frequency vibration. A series of hole were drilled on steel plates to evaluate the effect of vibration on material removal rate and hole quality. Infinite focus optical technique was used to capture and analyze the three-dimensional images of ECM'ed features. Experimental results showed that maximum machining depth and minimum taper angle can be achieved when vibrating the workpiece at 40 Hz and 10 µm amplitude. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at this vibration frequency and amplitude. Machining depth and material removal rate has a positive correlation with the average flushing speed. Sharper ECM’ed profile is obtained since the taper angle is favorably reduced at high average flushing speed.
Laser welding processes offer significant advantages such as high welding speed, narrow heat affected zone and quality of the welding joint. In this study, the process parameters of laser power and welding speed were modified for AISI 1018 steel plates of 8 mm thickness and compared using finite element method. The results of cross-section microstructure, heat affected zone and fusion zone were characterized. The grain refinement was affected as the parameters were modified. Tensile and microhardness tests were performed to determine the mechanical properties of the welding joints. Microhardness increased in fusion zone and decreased in heat affected zone. Tensile test showed ductile fracture in heat affected zone of the welding joints. The simulated profiles were compared with the experimental observations showing a reasonable agreement.
Electrical discharge machining is a machining method generally used for machining hard metals, those that would be high cost or have poor performance to machine with other techniques using, e.g., lathes, drills, or conventional machining. Therefore, also known as thermal processes like EDM, Plasma or Laser cutting can be used in drilling operations with poor metallurgical quality on cutting edge and will be necessary complement with other processes such as electrochemical machining (ECM). Both ECM and EDM processes use electrical current under direct-current (DC) voltage to electrically power the material removal rate (MRR) from the workpiece. However in ECM, an electrically conductive liquid or electrolyte is circulated between the electrode(s) and the workpiece for permitting electrochemical dissolution of the workpiece material. While the EDM process, a nonconductive liquid or dielectric is circulated between the cathode and workpiece to permit electrical discharges in the gap there between for removing the workpiece material. Both are principle too different, EC using an electrical conductive and ED using a dielectric medium. But exist a way that can to do a combination of Pulsed EC + ED Simultaneous and allowing the coexist both process, in a semidielectric medium, where both condition exist in the same time, therefore in this hybrid is possible create a tooling device dual cathode for drilling process with promissory advantages fast hole for this innovative hybrid ECDM Simultaneous, this hybrid it’s knew as blue arc drilling technology.
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