& In this work a theoretical analysis of the ECM process of curvilinear surfaces has been presented. The purpose of this analysis is to predict the shape evolution of the machined object using: a shaping surface of small thickness (flat issue) and a blade of hydrodynamic machine (quasi-three dimensional issue). ECM modeling involves prediction of the machined surface shape evolution and distribution of physical-chemical parameters inside the interelectrode gap. The problem has been solved with the use of an equation of the electrolyte and hydrogen mixture (liquid and gas) flat flow inside the interelectrode gap. After introducing simplifying assumptions for the flow, void fraction distribution and the gap thickness, the equations were solved partly analytically, partly numerically. The obtained solutions for assigned parameters of the machining process are presented graphically in the form of distributions of: static pressure, the mixture flow rate, temperature, void fraction and evolution of the machined surface shape evolution.
Abstract. The paper presents the results of experimental studies of electrochemical machining process oriented on occurring in the treatment critical states caused by electrolyte flow hydrodynamic conditions in the gap between electrodes. Material forming in electrochemical machining is carried out by anodic dissolution. In general in ECM process, the essence of the treatment is that the workpiece is the anode and the tool is the cathode. The space between the anode and cathode is filled by electrolyte. The current flow between the electrodes causes anodic dissolution process, resulting in the removal of material from the anode. Choosing in the process of electrochemical machining, respectively: anode and cathode material, electrolyte and processing parameters, such conditions can be created that enable a high process efficiency and smoothness of the surface. Inappropriate selection of machining parameters can cause the emergence of critical states in the ECM, which are mainly related to the flow of the electrolyte in the gap between electrodes. This work is an attempt to assess the occurring critical states in ECM on the example of machining of curved surfaces with any sort of outline and curved rotating surfaces.
The paper presents the authors’ model for the adaptive control of the electrochemical machining (ECM) process of machining the rotary (axisymmetric) elements of any curvilinear shape, using the results of theoretical computer simulation of this process. Computer simulations have been based on the authors’ model of the ECM of rotary surfaces of any curvilinear shape. The quasi- 3D ECM model proposed facilitates an analysis of physical phenomena which occur in the interelectrode gap. Mathematical ECM modelling has been based on the application of the equation of the workpiece shape evolution and on the system of partial differential equations resulting from the principle of mass conservation, momentum and the law of conservation of energy describing a flow of the mixture of electrolyte in the interelectrode gap. A solution to the problem has been developed with analytical and numerical integration. For the rotary hemispheric surface, in a set time, the local machining of a change in the interelectrode gap thickness and characteristic physicochemical parameters were determined, especially static pressure distribution, electrolyte flow velocity, temperature and volumetric gas phase concentration as well as current density. The simulation results were experimentally verified by determining the distribution of the shape deviation (WP) calculated from the process computer simulation and after the ECM. Applying the adaptive control of the ECM process has facilitated, based on the simulations made, enhancing the process stability and avoiding the occurrence of critical states.
In this paper the steady laminar flow of viscous incompressible ferromagnetic fluid is considered in a slot between fixed surfaces of revolution having a common axis of symmetry. The boundary layer ferromagnetic equations for axial symmetry are expressed in terms of the intrinsic curvilinear orthogonal coordinate system x, θ ,y.The method of perturbation is used to solve the boundary layer equations. As a result, the formulae defining such parameters of the flow as the velocity components v x , v y , and the pressure , were obtained.
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