The relationship between total current, applied potential, electrolyte flow rate, electrolyte conductivity, and electrode gap in electrochemical machining was investigated experimentally and analytically. An electrolytic cell was designed permitting the electrode gap to be observed and photographed. A 0.25 × 0.375-in. rectangular 1100F aluminum anode was used. Electrode gap varied between 0.013 and 0.033 in. The electrolyte was potassium chloride in concentrations from 0.67 normal to 1.7 normal. Current density range was 40–450 amp/in. and electrolyte flow rate was 0.22 to 0.98 gal/min. The photographs taken of the electrode gap during operation clearly show development of a hydrogen bubble layer next to the cathode. Based upon a mathematical model incorporating the bubble layer, an equation in a nondimensional form has been derived describing the functional relationship between process variables. This equation correlates the experimental data within plus or minus 15 percent. An equation which predicts the local current distribution, and hence anode dissolution rate, along the electrode gap in the direction of electrolyte flow is also presented. Based on the theoretical analysis, optimum operation in electrochemical machining from the standpoint of uniformity of metal removal is discussed.
In electrochemical machining the evolution of gas and heat in the electrolyte results in local variation of the gap between the electrodes. The ability to predict these variations for any given operating condition is a prerequisite of proper design of the cathode tool. This paper provides analytical predictions of the change in gap geometry for the one-dimensional steady-state case. Employing the basic conservation laws, a system of coupled nonlinear differential equations is derived for the gas-electrolyte mixture which flows between the electrodes. The assumption of homogeneity of the two-phase mixture is employed throughout the analysis. Numerical results from the solution of the equations are presented graphically and compared with experimental data. The local variation in gap and the relation between current, gap, and applied voltage compare favorably with the experimental data within the ranges of parameters investigated: current density 45–400 amps per sq in., electrolyte flow rate 0.22–0.98 gpm, entrance gap size 0.015–0.020 in., potassium chloride electrolyte normality 0.67–1.14.
A method of polishing metals by means of an electrolytic jet at extremely high current densities (to 1750 amps per sq in.) is described. Data are presented on the relation of polishing effect on various metals to current density and electrolyte flow rate for several electrolytes. An experimental method is described whereby the relationship of the above factors can be determined. It was found that all metals investigated could be polished at high enough current densities. Previous theories of electrolytic polishing are discussed and shown to not fully account for the process investigated. A modified theory to account for polishing at the high current densities observed is presented and is supported by mathematical analysis based on fundamental mass transfer considerations.
Unlike systems of batch analysis, continuous flow systems possess kinetic parameters. Associated with the steady state are such measurements as noise level and drift. This study reports on kinetic parameters associated with the transient state between the steady states including time required to change from base-line steady state to sample steady state and vice versa, characteristics of this change, time interval between samples, proportionality of sampling and washing time, fraction of steady state reached in any given sampling time, and interaction between samples. The transition between steady states has been found to obey first order kinetics to a good first approximation. This observation enables correlation of all of the above listed properties in quantitative fashion using new characteristic constants for continuous flow-the half-wash time (W1/2) and the lag phase time (L). These parameters, well known in other contexts such as radioactivity, can be employed as "figures of merit" for any continuous flow system or component, can be utilized to calculate performance characteristics, and are useful in evaluating and optimizing over-all performance.
Data are presented covering the effect of several variables on grinding rate for the electrolytic grinding process. The relative amount of material removal due to electrolysis and due to conventional grinding action was investigated. The Faraday current efficiency of the electrolytic part of the process was found to be near 100 per cent to the extremely high current density of 700 amps per sq in. This is thought to result from the scraping action of the wheel abrasive which prevents passivation of the work anode. Several phenomena of the process are explained on the basis of hydrogen gas pressure in the work-wheel interface. A formula is presented for calculating the hydrogen gas pressure. Equations are proposed for the basic chemical reactions of the process.
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