Flow field design and process stability in electrochemical machining of diamond holes

Zhao, Jianshe; Wei, Feng; Zhuang, Lei; Xiangli, Zhang; Gan, Weimin; Tian, Zongjun

doi:10.1016/j.cja.2016.07.005

Cited by 18 publications

(3 citation statements)

References 21 publications

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“…(c) the uid adheres to the principles of mass and momentum conservation. Given the complex geometry of the electrolyte uid ow path in the ECM processing gap region, the ow eld simulation employed the k-𝜔 turbulence model, based on Navier-Stokes equation [22][23][24]:…”

Section: Electrolyte Ow Distribution In Ecm Processing Gap Regionmentioning

confidence: 99%

A combined process of electrochemical machining and slotting for semi-blind hole involute internal splines enhanced by a new cathode design

Huang,

Fang,

et al. 2024

Preprint

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Machining complex internal structures in high-hardness materials presents a significant challenge. Conventional cutting methods often suffer from issues such as extensive tool wear and prolonged production cycles. This research proposes a combined process that integrates roughing electrochemical machining (ECM) with a precision slotting to achieve fast involute internal spline shaping of intricate high-hardness components. To enhance the process stability of the spline ECM process, a curved cathode design tailored for ECM is introduced. Flow field simulations demonstrate that the proposed curved cathode design leads to a relatively uniform distribution of electrolyte flow in the machining area. A dedicated ECM fixture and system are established for conducting experiments. The obtained ECM outcomes substantiate the commendable capacity of the optimized curved cathode to accomplish high precise and efficient machining and shaping of splines. Consequently, the optimized curved cathode design exhibits substantial potential for widespread application in the large-scale production of intricate internal cavity components composed of challenging-to-machine materials.

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Section: Electrolyte Ow Distribution In Ecm Processing Gap Regionmentioning

confidence: 99%

A combined process of electrochemical machining and slotting for semi-blind hole involute internal splines enhanced by a new cathode design

Huang,

Fang,

et al. 2024

Preprint

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show abstract

“…Various methods are used to fabricate the special-shaped holes pattern or surface texturing including laser beam machining [1,2], electrochemical machining [3,4], electrical discharge machining (EDM) [5], reactive ion etching [6], abrasive jet machining [7], chemical etching [8], photolithography [9], etc. ECM technology is applied for rapidly and flexibly producing these hole structures in metallic parts with good structural performance, like titanium alloy [10] and hard metals WC/Co [11], that is independent from the hardness and toughness of the material and without any mechanical and thermal impact [12,13].…”

Section: Introductionmentioning

confidence: 99%

“…Gu et al [20] have theoretically and experimentally investigated the cathode tool structure influence on the machining accuracy of blade fabrication in the electrochemical trepanning process. Zhao et al [4] have fabricated diamond holes on the metal grille.…”

Section: Introductionmentioning

confidence: 99%

Experiment and Modelling of Triangular Holes Array by Non-traditional Machining Process

Wang

Yang

et al. 2022

J. Phys.: Conf. Ser.

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Triangular holes array is a common structure of the specially shaped holes that can be used for various products in aerospace vehicles. These are commonly produced in the electrochemical machining (ECM) process. The high-quality and accuracy of a triangular grid are closely related to the processing parameters of cathode structure and sidewall insulation sleeve, power supply, electrolyte flow rate, feed speed, and machining gap. Simulations have been carried out to consider the influence of parameters including structure and dimension of the cathode, initial machining gap, feed speed, and current on the homogeneity of the flow field in the machining gap. Consequently, the modeling can support the design of the cathode. The paper is divided into two parts. Firstly, the tool cathode is simulated and fabricated. Secondly, the triangular holes array is produced by using the designed cathode tool. It was found that higher feed speed and lower machining gap increase the stability, accuracy, and efficiency of the machining process and the quality of the triangular holes array.

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Cathode cross tank and return hole optimization design and experiment verification of electrochemical machining closed integral impeller outside flow channels

Tang

Zhao

et al. 2018

Int J Adv Manuf Technol

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Flow field design and process stability in electrochemical machining of diamond holes

Cited by 18 publications

References 21 publications

A combined process of electrochemical machining and slotting for semi-blind hole involute internal splines enhanced by a new cathode design

A combined process of electrochemical machining and slotting for semi-blind hole involute internal splines enhanced by a new cathode design

Experiment and Modelling of Triangular Holes Array by Non-traditional Machining Process

Cathode cross tank and return hole optimization design and experiment verification of electrochemical machining closed integral impeller outside flow channels

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