Electrochemical machining gap prediction with multi-physics coupling model based on two-phase turbulence flow

Chen, Yuanlong; Xiaochao, Zhou; Chen, Peixuan; Ziquan, Wang

doi:10.1016/j.cja.2019.03.006

Cited by 37 publications

(10 citation statements)

References 20 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The application of computer-aided design and finite element method in cathode design speeds up the development of design work, which can effectively reduce the cost of electrochemical machining and improve the machining efficiency [21][22][23][24]. Professor Chen research team established the single-phase fluid turbulence model of blade electrochemical machining process, and obtained a series of research results such as the variation law of anode profile, inter electrode temperature distribution, electrolyte flow rate distribution and electrolyte pressure distribution in the whole electrochemical machining process [25][26][27][28]. Ji carried out the combined EDM electrolytic machining of hole expansion.…”

Section: Lin Tang ( ) •Xingchen Ge • Chengjin Shi • Lifeng Zhang • Kaige Zhaimentioning

confidence: 99%

Multi-stage Inner Conical Hole Hydraulic Self Driving Rotating Magnetic Field Assisted Electrolytic Machining

Tang

Shi

et al. 2021

Preprint

View full text Add to dashboard Cite

Aiming at the problem of poor surface quality of multi-stage inner conical hole parts in electrochemical machining, a hydraulic self driving rotating magnetic field assisted electrochemical machining method is proposed, a hydraulic self driving rotating flow field model is established and simulated, and the structure of cathode tail blades is optimized. The simulation results show that when the number of cathode blades is 3 and the thickness of blades is 0.8mm, When the electrolyte flow rate is not less than 5m/s, the impeller at the tail of the cathode mandrel can rotate stably. A hydraulic self driving rotating magnetic field assisted electrochemical machining cathode is designed. When the machining voltage is 10V, the electrolyte temperature is 30 ℃, the electrolyte pressure is 1.6Mpa, the cathode feed speed is 5mm / min, and the electrolyte is 5%NaCl+16%NaNO3+4%NaClO3 composite electrolyte, the comparative experimental study of multi-stage inner conical hole electrochemical machining process with and without rotating magnetic field is carried out, The results show that the surface roughness of the workpiece without magnetic field is Ra0.847μm under the same processing parameters . With the addition of rotating magnetic field, the surface roughness of the workpiece is Ra0.437μm. The surface quality was improved by 48.41%.

show abstract

Section: Lin Tang ( ) •Xingchen Ge • Chengjin Shi • Lifeng Zhang • Kaige Zhaimentioning

confidence: 99%

Multi-stage Inner Conical Hole Hydraulic Self Driving Rotating Magnetic Field Assisted Electrolytic Machining

Tang

Shi

et al. 2021

Preprint

View full text Add to dashboard Cite

show abstract

“…Schaarschmidt et al [18] studied the characteristics of precision ECM with pulse and vibration coupling through multi-physical field coupling simulation. Chen et al [19] predicted the ECM gap using a multi-physical field coupling simulation based on two-phase turbulence flow. Wang et al [20] studied the formation process of rhomboid holes in pulse and vibration coupling ECMs based on multi-physical field coupling simulation.…”

Section: Introductionmentioning

confidence: 99%

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Wang

Deng

et al. 2023

Metals

View full text Add to dashboard Cite

Large size TiAl alloy blade is one of the important parts to reduce the weight of advanced aero-engines. However, the precision manufacturing of such blades is a challenge due to their large size, low ductility at room temperature, and high hardness of the TiAl alloy. Electrochemical machining (ECM) is a very promising method for the precision manufacturing of such blades, considering its unique advantages. In this study, a very comprehensive multi-physical field coupling simulation and pulse ECM experiments on large size TiAl alloy blades are carried out. Geometric and theoretical models involving electric fields, gas-liquid two-phase flow, heat transfer, and anodic dissolution are developed. The variation of bubble, temperature, electrolyte flow rate, and electrical conductivity at the outlet and the different areas on the blade surface with the processing time and distribution along the flow channel in the machining gap are revealed by simulation. It is found that the influence of electrolyte temperature on electrical conductivity is more dominant than that of bubble concentration. Finally, the experiments of pulse ECM on large size TiAl alloy blade are carried out, and the experimental results are analyzed in detail. The high efficiency and high surface quality of large size TiAl alloy blades are realized. The surface roughness and machining accuracy of the blade are about Ra 0.9 μm and 0.18 mm, respectively.

show abstract

“…The use of the laminar N-S model reduces the heat transfer effect, making the prediction accuracy of the simulation model low. In Chen et al [23] and Zhou et al [24], a multiphysics field coupled simulation model for the ECM of turbine blades was established based on the gas-liquid two-phase turbulent flow k-ε model, and the effects of electrolyte temperature distribution and bubble rate distribution on the accuracy of the ECM of turbine blades were fully considered. The results show that the simulation model is highly accurate in predicting the machining accuracy of turbine blades.…”

Section: Introductionmentioning

confidence: 99%

Simulation Analysis of Multi-Physical Field Coupling and Parameter Optimization of ECM Miniature Bearing Outer Ring Based on the Gas-Liquid Two-Phase Turbulent Flow Model

Cao

2022

Micromachines

View full text Add to dashboard Cite

Electrochemical machining (ECM) is an essential method for machining miniature bearing outer rings on the high-temperature-resistant nickel-based alloy GH4169. However, the influence of electrolyte temperature distribution and bubble rate distribution on electrolyte conductivity in the ECM area could not be fully considered, resulting in the simulation model not being able to accurately predict the machining accuracy of the outer ring of the miniature bearing, making it challenging to model and predict the optimal process parameters. In this paper, a multiphysics field coupled simulation model of electric, flow, and temperature fields during the ECM of the miniature bearing outer ring is established based on the gas–liquid two-phase turbulent flow model. The simulation analyzed the distribution of electrolyte temperature, bubble rate, flow rate, and current density in the machining area, and the profile change of the outer ring of the miniature bearing during the machining process. The analysis of variance and significance of machining voltage, electrolyte concentration, electrolyte inlet flow rate, and interaction on the mean error of the ECM miniature bearing outer rings was derived from the central composite design. The regression equation between the average error and the process parameters was established, and the optimal combination of process parameters for the average error was predicted, i.e., the minimum value of 0.014 mm could be achieved under the conditions of a machining voltage of 16.20 V, an electrolyte concentration of 9.29%, and an electrolyte inlet flow rate of 11.84 m/s. This is important to improve the machining accuracy of the outer ring of the ECM miniature bearing.

show abstract

Electrochemical machining gap prediction with multi-physics coupling model based on two-phase turbulence flow

Cited by 37 publications

References 20 publications

Multi-stage Inner Conical Hole Hydraulic Self Driving Rotating Magnetic Field Assisted Electrolytic Machining

Multi-stage Inner Conical Hole Hydraulic Self Driving Rotating Magnetic Field Assisted Electrolytic Machining

Multi-Physical Field Coupling Simulation and Experiments with Pulse Electrochemical Machining of Large Size TiAl Intermetallic Blade

Simulation Analysis of Multi-Physical Field Coupling and Parameter Optimization of ECM Miniature Bearing Outer Ring Based on the Gas-Liquid Two-Phase Turbulent Flow Model

Contact Info

Product

Resources

About