A novel current sensor indicator enabled WAFTR model for tool wear prediction under variable operating conditions

Kundu, Pradeep; Luo, Xichun; Qin, Yi; Chang, Wenlong; Kumar, Anil

doi:10.1016/j.jmapro.2022.08.036

Cited by 5 publications

(1 citation statement)

References 38 publications

(52 reference statements)

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“…In the aerospace industry, there are many complex parts manufactured by difficultto-machine materials such as flame tubes, helicopter propeller hubs, engine blades, and aero-engine casings [1][2][3][4]. Conventional mechanical methods are used to manufacture these parts, and the tool wear is so serious that it is necessary to replace the tool frequently [5,6]. Due to the long processing cycle, low processing efficiency and high processing cost, it is a great challenge for conventional mechanical methods to fabricate these parts manufactured by using difficult-to-machine materials [7,8].…”

Section: Introductionmentioning

confidence: 99%

Evolution of the Interelectrode Gap during Co-Rotating Electrochemical Machining

Zhou,

Wang,

et al. 2023

Metals

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A new co-rotating electrochemical machining method is presented to machine the complex structure inside annular parts such as flame tubes and aero-engine casings. Due to the unique shape and motion of electrodes, it is difficult to accurately compute the electric field intensity in the machining area. In this paper, the complex electric field model is simplified by conformal transformation, and the analytical solution of electric field intensity is exactly calculated. A material removal model is built on the basis of the electric field model, and the dynamic simulation of the material removal process is realized. The effects of the cathode radius, applied voltage, feed rate and initial interelectrode gap on the interelectrode gap (IEG) and material removal rate (MRR) are analyzed. The simulation results indicate that the MRR is always slightly less than the feed rate in a quasi-equilibrium state, resulting in a slow reduction in IEG. In addition, the final machining state is not affected by the initial IEG, and the MRR in a quasi-equilibrium state is determined by the feed rate. Several comparative experiments were carried out using the optimized processing parameters, in which the MRR and IEG were measured. The convex structures were successfully machined inside the annular workpiece with optimum machining parameters. The experimental results are in good agreement with the theoretical results, indicating that the established model can effectively predict the evolution process of MRR and IEG.

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