Effect of solution conductivity on tool electrode wear in electrochemical discharge drilling of nickel-based alloy

Zhang, Chenxiang; Xu, Zhengyang; Hang, Yusen; Xing, Jun

doi:10.1007/s00170-019-03492-w

Cited by 21 publications

(7 citation statements)

References 32 publications

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“…Electrolytic machining does not depend on the physical properties of the material, such as hardness, toughness, and mechanical strength, so it is suitable for machining deep holes of small diameter and adding such holes to difficult-to-machine cemented carbides. Electrochemical machining involves many factors, such as electrochemistry, heat transfer, hydrodynamics, etc., and its dissolution and formation state is complex and cannot be directly measured [5,6]. Many scholars have conducted numerous theoretical and experimental studies on the electrochemical dissolution mechanism of materials during electrolytic processing, mainly including simulation analysis of the steady-state process of electrolytic processing of pore structures and experimental and process optimization studies, with good research results being achieved [7][8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Experimental Research and Multi-Physical Field Coupling Simulation of Electrochemical Machining Based on Gas–Liquid Two-Phase Flow

Dai

2022

Micromachines

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In this paper, the forming mechanism of cooling hole electrolytic machining is studied using multi-physical field coupled simulation and experimental observation. A multi-physical field coupled simulation model was established to obtain the gas–liquid two-phase distribution law inside the machining gap, and a mathematical model of gas–liquid two-phase flow was established to analyze the change law of the size and morphology of cooling hole electrolytic machining under different process parameter conditions. The simulation and experimental results show that the size of the inlet of the cooling hole is larger, the size of the outlet is smaller, and the middle section is more stable; machining voltage and electrode feed speed have a significant influence on the size and shape of heat dissipation holes. Compared with the experimental data, simulation accuracy is good.

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Section: Introductionmentioning

confidence: 99%

Experimental Research and Multi-Physical Field Coupling Simulation of Electrochemical Machining Based on Gas–Liquid Two-Phase Flow

Dai

2022

Micromachines

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“…Its dissolution and formation state are complex, which cannot be directly determined [ 14 , 15 ]. Many scholars have carried out a lot of simulation and theoretical research according to the morphology of pore structure and the dissolution and removal of materials after electrochemical processing [ 16 , 17 , 18 , 19 , 20 ]. Electrochemical machining technology and theory are improving day by day.…”

Section: Introductionmentioning

confidence: 99%

Simulation Analysis and Process Evaluation of Cooling Hole Forming Precision in Mask Assisted Electrochemical Machining Based on GH4169

Dai

2022

Materials

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Good heat dissipation performance of aero-engine an effectively improve the service performance and service life of aero-engine. Therefore, this paper studies the machining method of cooling holes of high-temperature existent material GH 4169 for aero-engine innovatively puts forward the mask electrochemical machining method of cooling holes and explores the entrance morphology and taper formation law of the hole structure of high-temperature resistant material GH 4169. The mathematical model of anode dissolution of cooling holes in ECM is established, and the influence of voltage and electrolyte flow rate on cooling holes in ECM is analyzed. Compared with the mask-less electrochemical machining, the inlet radius of cooling holes in mask electrochemical machining is reduced by about 16.0% and the taper is reduced by 52.8% under the same machining parameters, which indicates that the electrochemical machining efficiency of mask is higher and the machining accuracy is better. Experiments show that the diameter of the mask structure improves the accuracy of the inlet profile of the cooling hole in the ECM. The diameter of the mask increases from 2 mm to 2.8 mm, and the inlet radius of the cooling hole increased from 1.257 mm to 1.451 mm When the diameter of the mask is 2.2 mm, the taper of the cooling hole decreased by 53.4%. The improvement effect is best, and the thickness of the mask has little influence on the forming accuracy of the cooling hole.

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“…The papers found in literature discussing the electrochemical machining of the surfaces of revolution concern mostly the machining of frontal and lateral surfaces of rotary workpieces, electrochemical grinding, and treatment which involves deburring, calibrating holes, and smoothing the rotary surfaces [ 33 , 58 , 59 , 60 , 61 ].…”

Section: Introductionmentioning

confidence: 99%

Electrochemical Machining of Curvilinear Surfaces of Revolution: Analysis, Modelling, and Process Control

Sawicki

Paczkowski

2022

Materials

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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.

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Effect of solution conductivity on tool electrode wear in electrochemical discharge drilling of nickel-based alloy

Cited by 21 publications

References 32 publications

Experimental Research and Multi-Physical Field Coupling Simulation of Electrochemical Machining Based on Gas–Liquid Two-Phase Flow

Experimental Research and Multi-Physical Field Coupling Simulation of Electrochemical Machining Based on Gas–Liquid Two-Phase Flow

Simulation Analysis and Process Evaluation of Cooling Hole Forming Precision in Mask Assisted Electrochemical Machining Based on GH4169

Electrochemical Machining of Curvilinear Surfaces of Revolution: Analysis, Modelling, and Process Control

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