Energy-based Analysis of Material Dissolution Behavior for Laser-Chemical and Electrochemical Machining

Mehrafsun, Salar; Harst, Simon; Hauser, Olga; Eckert, Sandro; Klink, Andreas; Klocke, Fritz; Vollertsen, Frank

doi:10.1016/j.procir.2016.02.128

Cited by 7 publications

(7 citation statements)

References 6 publications

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“…During the first process, the material is heated locally and chemical reactions are therefore thermally activated. In ECM the material is dissolved by an electric field support [33]. From a superordinate point of view the necessary energy for initiating chemical reactions can be provided in both ways thermally or electrically or even by a combination of them [33].…”

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

“…In ECM the material is dissolved by an electric field support [33]. From a superordinate point of view the necessary energy for initiating chemical reactions can be provided in both ways thermally or electrically or even by a combination of them [33]. For both processes the formation of an initial passivating layer is very important to avoid excessive and uncontrolled general dissolution and allowing the distinct transpassive material removal when locally increasing the according material loadings.…”

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

“…Future modeling approaches for Process Signature Components of processes with chemical and thermochemical impact will focus on a more comprehensive energy-based description based on the Gibbs free energy, cf. [33]. It is assumed that this will allow a persistent modeling approach also enabling inverse approaches to deduce appropriate process parameter settings to achieve Fig.…”

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

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Underlying Mechanisms for Developing Process Signatures in Manufacturing

et al. 2018

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The concept of Process Signatures allows the reliable and knowledge-based prediction of material modifications (e.g., changes of hardness, residual stress, microstructure and chemical composition) researchers in the field of surface integrity, and manufacturing technologies have already been seeking for a long time. A Process Signature is based on the correlation between the internal material loads in manufacturing processes (e.g., stress, strain, temperature) and the resulting material modifications. The target of this paper is to get a comprehensive view on the development of single Process Signature Components for processes with different predominant impacts. Particularly, a mechanism-based approach leading to significant descriptives of internal material loads for a specific material modification is proposed. By this, a deeper understanding of the underlying mechanisms leading to changes of the workpiece surface layer properties caused by manufacturing processes is provided. The challenging identification of significant mechanisms and descriptives of internal material loads is highlighted for each process, and supporting measurement methods and modeling approaches are presented. Process Signatures are expected to enable the solution of the so-called inverse problem in manufacturing.

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Section: Exemplary Process Signature Componentmentioning

confidence: 99%

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

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Underlying Mechanisms for Developing Process Signatures in Manufacturing

et al. 2018

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“…Additional investigations on the influence of temperature on the passivation behavior for 42CrMo4 steel in 2.5 M sodium nitrate solution at temperatures between 20°C and 50°C revealed an increase of the active and transpassive current density as well as a less pronounced passive region with increasing electrolyte temperature. [ 16 ]…”

Section: Introductionmentioning

confidence: 99%

Impact of rim zone modifications on the surface finishing of ferritic–pearlitic 42CrMo4 using electrochemical machining

Zander

Schupp

Mergenthaler

et al. 2021

Materials & Corrosion

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The efficiency of material removal using electrochemical machining (ECM) is highly dependent on the initial rim zone modifications of the material to be processed. The influence of the rim zone modifications, such as topography and microstructure, on ECM, is investigated on ferritic–pearlitic 42CrMo4 steel by experiment and simulation. 42CrMo4 steel in two different premachining states—ground and electric discharge machined (EDM)—is subjected to a subsequent surface finishing by ECM in sodium nitrate solution. Before and after ECM, the topography and microstructure are examined using scanning electron microscopy, X‐ray diffractometer, and topography analysis methods. The electrochemical properties of the material are determined by potentiodynamic polarization. The efficiency of surface finishing by ECM is quantified by mass spectroscopic analysis (inductively coupled plasma mass spectrometry) of the process electrolyte and related to the rim zone modifications by simulation. The results reveal that the efficiency of material removal during ECM is higher for EDM than for ground 42CrMo4. This is attributed to an increased roughness of EDM 42CrMo4 and to the unfavorable electrochemical properties of the cementite phase in ground 42CrMo4.

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“…LCM and ECM have quite similar mechanisms of dissolution and surface modification. These processes have the common feature that material removal is based on the chemical dissolution on an atomic scale [Meh16a]. In LCM the material removal is accomplished by the laser-induced chemical reaction between an electrolyte and the metallic surface of the workpiece [Now94] and is mainly dependent on the laser-induced temperature distribution over the workpiece surface [Mes17a].…”

Section: Introductionmentioning

confidence: 99%

Tooling

Vollertsen

Seven

Messaoudi

et al. 2019

Lecture Notes in Production Engineering

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Micro metal parts are usually produced in large lot sizes at high production rates. In order to achieve sufficient product quality, excessive tool wear has to be avoided. In the micro range, so-called scaling effects and their influence on tool wear in micro forming have not been investigated so far. For the investigation, tests in micro deep drawing were carried out with metal sheets (s < 50 μm) of pure aluminum Al99.5, a copper alloy E-Cu58 and stainless steel 1.4301. The failure mechanisms of the micro cups produced were identified as bottom fracture and cup wall damage, and tool wear was measured and characterized with optical measurements and EDX analyses. Moreover, micro cups can be produced by DLC-and PVD-coated tools in a dry forming process. To investigate the wear behavior in a continuous process, a forming tool was developed with an integrated blanking and deep drawing die. The tool wear was measured optically, and the wear mechanisms could be identified in a combined micro and deep drawing process. As a result, the tool could be modified by a manufacturing in selective laser melting and the tool life increased by 290%. Furthermore, a method for tool wear examination in long-term tests was developed. In lateral micro upsetting, the tool wear history can be examined by analyzing the formed product. Several tool materials and coatings were tested with up to 500,000 strokes.

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Energy-based Analysis of Material Dissolution Behavior for Laser-Chemical and Electrochemical Machining

Cited by 7 publications

References 6 publications

Underlying Mechanisms for Developing Process Signatures in Manufacturing

Underlying Mechanisms for Developing Process Signatures in Manufacturing

Impact of rim zone modifications on the surface finishing of ferritic–pearlitic 42CrMo4 using electrochemical machining

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