Implementation of the Machine Tool-Specific Current and Voltage Control Characteristics in Multiphysics Simulation of Electrochemical Precision Machining

Schaarschmidt, Ingo; Hackert-Oschätzchen, Matthias; Meichsner, Gunnar; Zinecker, Mike; Schubert, Andreas

doi:10.1016/j.procir.2019.04.142

Cited by 9 publications

(6 citation statements)

References 3 publications

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“…Ghislain REMY (Remy et al 2006) proposed to design resonant controllers of the current control loop by using the inversion principle of the Causal Ordering Graph (COG) representation of a PMLSM model. Ingo Schaarschmidt (Schaarschmidt et al 2019) studied implementation of the machine tool-specific current and voltage control characteristics in multi-physics simulation of electrochemical precision machining.…”

Section: Influence Of Electrical Parameters On Precision Machinementioning

confidence: 99%

Electric-Magnetic-Mechanical Coupling in Precision Machines

Ren¹

2020

Precision Manufacturing

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In this chapter, the electric-magnetic-mechanical coupling methods and related research progress of precision machine tools are discussed. The electromagnetic machine complex of guideway and spindle and the influence of electromagnetic machine parameters on precision machining equipment are discussed respectively based on the key functional parts of precision machine tools. Then, the electromagnetic coupling, motor coupling, and magnetic machine coupling are analyzed respectively to study the coupling of three technical directions, and the method involves the finite element analysis method and electromagnetic machine test method of electromagnetic machine. Based on a specific machining process example, this chapter discusses the theoretical analysis of the influence of three parameters of electromagnetic machine on precision machining machine tools. Finally, the summary analysis of this chapter needs to study the systematic

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Section: Influence Of Electrical Parameters On Precision Machinementioning

confidence: 99%

Electric-Magnetic-Mechanical Coupling in Precision Machines

Ren¹

2020

Precision Manufacturing

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“…Studies done so far on the design of ECM tools have to deal with approximations related to the fact that local physical effects create significant differences between the simulated design and the real one. Some of these discrepancies and their causes have already been addressed in the ECM simulation literature [5,6]. During the electric current pulse, material dissolution takes place.…”

Section: Introductionmentioning

confidence: 99%

“…Research efforts have been focused on ECM process modelling and simulation, primarily concerning tool geometry prediction and workpiece shape generation [3]. In the last ten years, the research in computer simulation and process optimisation techniques to predict and control the ECM process has increased by several factors [4][5][6]. Most simulation research uses COMSOL® [7] to deal with the multiphysics aspects of the process, which despite its many advantages, seems intrinsically limited in the accuracy of its results as its electrolyte flow solutions are based on finite element method (FEM) instead of its more adequate counterpart, the finite volume method (FVM), particularly suitable when dealing with computational fluid dynamics (CFD) [8].…”

Section: Introductionmentioning

confidence: 99%

Simulation of electrolyte behaviour of industrial electrochemical machining

Moro,

Sneddon,

Gomez-Gallegos

et al. 2023

Preprint

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Development of simulation models for electrochemical machining (ECM) is a widely researched challenge to avoid the traditional trial and error process, with potential resulting advantages in terms of time, cost, and sustainability. To this objective, it is crucial to utilise software that can accurately simulate the complex multiphysics aspects of ECM without being too computationally expensive and with a fast set up. This paper investigates an alternative finite element software to model ECM for industrial production. The specific features of this software make it attractive for industrial applications, and in this work, it is validated as suitable to model the electrolyte characteristics of flow rate and pressure. The model developed is the basis for determining local changes to electrolyte conductivity, current density, and efficiency as a function of gap spacing optimisation in order to achieve the desired geometry with dimensional accuracy and assure process repeatability for industrial production. Simulation results are in agreement with the experimental ECM carried out as part of this work.

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“…Higher temperature, hydrogen generation, and machining products affect the electrical conductivity of the electrolyte. 5 In the third step, the voltage is zero, and the tool moves up to the top zone of the oscillation range. Consequently, the IEG is bigger, and the electrolyte flushes away all the by-products of the machining and heat.…”

mentioning

confidence: 99%

“…Consequently, the IEG is bigger, and the electrolyte flushes away all the by-products of the machining and heat. 5 Choosing an optimum duty cycle and pulsed frequency is necessary for localized machining. 6 Furthermore, PECM results in an improved surface finish.…”

mentioning

confidence: 99%

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

Ghasemiansafaei,

Schaefer,

Hall

et al. 2023

J. Electrochem. Soc.

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Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials. The contactless nature of ECM and anodic dissolution of the workpiece propound no tool ablation. Nevertheless, in a few studies, tool damages, namely the formation of pits and geometrical changes, have been observed, which is the investigative goal of this work. This study considers three hypotheses to investigate tool changes during pulsed electrochemical machining (PECM) which are hydrogen embrittlement, cavitation erosion, and cathodic corrosion. A systematic study of monitoring possible tool (1.4112 martensitic stainless steel) changes during ECM and PECM in aqueous NaNO3 electrolyte is performed. Experimental results of this study show that hydrogen embrittlement and cavitation erosion are not the reason for causing changes in the tool. Cathodic corrosion might be the reason for the changes in the tool in this study; however, more investigation is needed. The approach in this study is investigating the microstructure of the tool regarding different aspects before and after ECM and PECM, as the microstructure stores information regarding phenomena occurring during any process.

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Implementation of the Machine Tool-Specific Current and Voltage Control Characteristics in Multiphysics Simulation of Electrochemical Precision Machining

Cited by 9 publications

References 3 publications

Electric-Magnetic-Mechanical Coupling in Precision Machines

Electric-Magnetic-Mechanical Coupling in Precision Machines

Simulation of electrolyte behaviour of industrial electrochemical machining

Analysis of Mechanisms Affecting the Tool in Pulsed Electrochemical Machining

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