A three-dimensional FEM model of channel machining by scanning micro electrochemical flow cell and jet electrochemical machining

Guo, Cheng; Qian, Jun; Reynaerts, Dominiek

doi:10.1016/j.precisioneng.2018.02.002

Cited by 19 publications

(7 citation statements)

References 32 publications

(39 reference statements)

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“…Consequently, tooling that is able to vector independently of translation is required. Considering Figure 1, when a profiling tool is used in EJP, the initial profile matches the tool geometry, in this case a symmetrical twin element (STE) nozzle [2,6] (Figure 1 starting profile). When applied in a constant vector toolpath, aligned with the intended orientation of the tool (Figure 1a), a constant profile is generated.…”

Section: Introductionmentioning

confidence: 99%

Direct-writing by active tooling in electrochemical jet processing

Mitchell-Smith

Bisterov

Speidel

et al. 2019

Manufacturing Letters

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Recent innovations in electrochemical jet processing have caused step changes in process flexibility and precision. However, utilisation of these innovations requires the development of new machine tool technology. Presented here is a new methodology enabling the exploitation of highly customisable energy density profiles regardless of toolpath vector whilst minimising any error from the intent profile. A further approach is defined whereby active tooling allows the energy density profile to be modulated as a function of position within the toolpath, giving rise to dynamic feature creation. Adoption of this methodology allows a new design freedom within electrochemical jet processes.

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Section: Introductionmentioning

confidence: 99%

Direct-writing by active tooling in electrochemical jet processing

Mitchell-Smith

Bisterov

Speidel

et al. 2019

Manufacturing Letters

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“…Initially, existing research in jet-ECM simulation and application is reviewed, followed by developing the proposed approach for process investigation. This work proposes a 3D finite element method (FEM) simulation model for channel machining using Scanning Micro Electrochemical Flow Cell (SMEFC) and Jet-ECM [16]. The FEM model is based on Faraday's law, a virtual thin electrolyte layer, and a moving mesh technique.…”

mentioning

confidence: 99%

“…Notably, the simulation enables the movement of electrolyte droplets over a relatively large range on the workpiece. The model concurrently determines the current density and potential distribution while altering the workpiece profile, thus enhancing the understanding of this type of ECM process [16]. Another study presents a multi-physical model for Jet-ECM simulation using COMSOL Multiphysics [17].…”

mentioning

confidence: 99%

Modeling of Jet Electrochemical Machining Using Numerical and Design of Experiments Methods

Mehrvar,

Motamedi,

Jamalpour

2023

Scientia Iranica

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Modeling and determining the optimal conditions for the jet electrochemical machining (Jet-ECM) process is critical. In this study, a hybrid approach combining numerical and design of experiments (DOE) methods have been applied to model and determine the optimal conditions for Jet-ECM. The voltage (V), inner tool diameter (I), initial machining gap (G), and electrolyte conductivity (C) are considered input variables. Additionally, dimensional accuracy (E) and machining depth (D) are response variables. Twenty-seven numerical simulations have been performed using the Box-Behnken design to implement the response surface methodology (RSM). Consequently, two mathematical models have been obtained for these response variables. The effects of the input variables on the response variables are investigated using statistical techniques such as variance analysis. Furthermore, the desirability function approach has been applied to determine the optimal conditions for dimensional accuracy and depth of machining. The results show that the optimal values for achieving maximum depth of machining while maintaining a dimensional accuracy of 0.05 mm are as follows: electrolyte conductivity of 8 S/m, voltage of 36.9 V, initial machining gap of 200 μm, and inner tool diameter of 0.4 mm.

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“…5 Guo et al put forward a three dimensional model to simulate the jet-EC milling process with coupling the electric field and the anode deformation. 6 However flow field analysis was not included in the model, and the electrolyte shape was predefined by camera observation and remained unchanged. As so far, although some multiphysics models have been applied in the simulation of the stationary jet-ECM, those models are unable to describe the process and predict the jet-EC milling process due to the absence of tool motion.…”

mentioning

confidence: 99%

Multiphysics Simulation and Experimental Investigation on Jet Electrochemical Milling of Ti-6Al-4V Alloy

Kong¹,

Qu²,

Kong³

2022

J. Electrochem. Soc.

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Jet electrochemical milling (jet-EC milling) is a promising technique for machining hard-to-cut metallic materials with high machining efficiency and flexibility. The process of the jet-EC milling of Ti-6Al-4V Alloy is difficult to predict due to the interaction of multiple physical fields and the formation of passivation film. In this work, a novel model is established to simulate the jet-EC milling and predict machining profile. In this model, the interactional relationships among electric field, two-phase flow field, and geometry deformation are considered using a multiphysics approach, and the breakdown process of the passivation film is involved for accurately predicting the machining results. In addition, the passivation film breakdown process of Ti-6Al-4V alloy is studied experimentally. Finally, several experiments on the jet-EC milling of Ti-6Al-4V alloy are conducted to verify the simulation results and discuss the influence of the travel rate on the material dissolution. The current density distribution on the anode surface is clarified. The proposed model is more in line with the experiments. By applying an appropriate travel rate, a sharp edge is obtained without stray corrosion as the electrolyte forms an upward reflection and the un-machined surface is free from stray corrosion due to the absence of the electrolyte.

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A three-dimensional FEM model of channel machining by scanning micro electrochemical flow cell and jet electrochemical machining

Cited by 19 publications

References 32 publications

Direct-writing by active tooling in electrochemical jet processing

Direct-writing by active tooling in electrochemical jet processing

Modeling of Jet Electrochemical Machining Using Numerical and Design of Experiments Methods

Multiphysics Simulation and Experimental Investigation on Jet Electrochemical Milling of Ti-6Al-4V Alloy

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