Multiphysics Simulation of Electrochemical Machining Process for Three-Dimensional Compressor Blade

Fujisawa, Toshiaki; Inaba, Kazuaki; Yamamoto, Makoto; Kato, Dai

doi:10.1115/1.2956596

Cited by 82 publications

(24 citation statements)

References 10 publications

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“…Where η is the current efficiency of anodic dissolution, ω is the electrochemical equivalent of the workpiece material, κ is the electrolyte conductivity with tool vibration, E is the electric field intensity, △U is the total overpotential between cathode and anode and △ b is the frontal gap. Considering the conductivity of electrolyte, Fujisawa et al [22] conducted the formula due to heating and gas generation as follows,…”

Section: Removal Theory Of Usemmmentioning

confidence: 99%

Mechanism of 6061 Aluminium Material Erosion in USEMM

Tong

Wang

et al. 2021

Preprint

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Micro-structure on metal surface can be created with high precision and good surface quality by ultrasonic-assisted electrochemical micromachining (USEMM). One of the prevalent material removal mechanisms in ultrasonic machining (UM) is cavitation erosion. However, the mechanism of material erosion is not clear and worth investigating. This study of the mechanical and chemical effects of the ultrasonic vibration in 6061 aluminium alloy is targeted to reveal the material processing mechanism in USEMM. Based on the built model, the velocity of micro-jet produced near the workpiece surface by ultrasonic cavitation reaches up to 350 m/s when bubble collapses computed by software MATLAB. The impact of micro jet produces plastic micro-pits on the metal surface and the convex peak around the edge of the pits, which is verified in ABAQUS software. The metallographic microscope and curves of the electrochemical polarization behaviour results indicate a significant grain refinement and a marked increase of anodic dissolution current, as well as a weaker resistance than the original workpiece in NaNO3 electrolyte during UM. The current-time curve during machining demonstrates the passive layer forms on the metal surface and then breaks down at the time of less than 0.0066s in USEMM. Micrographs of scanning electron microscope (SEM) of the machined surface in different stages show that many uniform and flat pits are formed in USEMM, compared with the local uneven pits in EMM.

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Section: Removal Theory Of Usemmmentioning

confidence: 99%

Mechanism of 6061 Aluminium Material Erosion in USEMM

Tong

Wang

et al. 2021

Preprint

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“…Giandomenico et al [ 4 ] investigated the nanosecond pulse power supply used in micro-ECM and utilized open source hardware to make the pulse generator with adjustable parameters, high precision, and low cost and verified its performance through experiments. To increase the quality of electrochemical machining, many researchers tried to optimize the flow field distribution via multi-physics field simulation, so as to further reduce the influence of non-uniform flow field on electrochemical machining [ 5 , 6 , 7 , 8 , 9 , 10 ]. Zhan et al [ 11 ] proposed a novel electrochemical machining technique, namely the plasma assisted electrochemical machining technique, and this technique tries to form a thin gas film and plasma layer around the tool electrode by optimizing the potential.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Influence of Tool Electrode Material on Electrochemical Micromachining of 304 Stainless Steel

Bian

et al. 2021

Materials

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Different cathode materials have different surface chemical components and machining capacities, which may finally result in different machining quality and machining efficiency of workpieces. In this paper, in order to investigate the influence of cathode materials on the electrochemical machining of thin-walled workpiece made of 304 stainless steel, five cylindrical electrodes are used as the target working cathodes of electrochemical machining to conduct experiments and research, including 45# steel, 304 stainless steel, aluminum alloy 6061, brass H62, and tungsten steel YK15. The stray current corrosion, taper, and material removal rate were used as the criteria to evaluate the drilling quality of efficiency of a thin-walled workpiece made of 304 stainless steel. The research results show that from the perspectives of stray current corrosion and taper, aluminum alloy 6061 is an optimal tool cathode, which should be used in the electrochemical machining of thin-walled workpieces made of 304 stainless steel; on the aspect of material removal rate, the 45# steel, 304 stainless steel, and aluminum alloy 6061 present close material removal rates, all of which are higher than that of brass H62 and tungsten steel YK15. Based on comprehensive consideration of both machining quality and machining efficiency, the aluminum alloy 6061 is the best option as the cathode tool in the electrochemical machining of thin-walled workpieces made of 304 stainless steel.

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“…The current efficiency is an important characteristic parameter that describes the relationship between the dissolution rate of the anode material and the current density in ECM [7]. The accurate measurement of the current efficiency is the basis for both anode shape prediction and cathode tool design [8][9][10]. However, the dissolution process of alloy materials is affected by elemental composition, electrochemical reaction valence, and material peeling action.…”

Section: Introductionmentioning

confidence: 99%

A Study of Precision Current Efficiency Curve Measurement with a Casing-Type Anode

2021

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Electrochemical machining (ECM) is a non-traditional machining technology that is widely used in the manufacturing of key components in the aviation industry. The current efficiency is defined as the ratio of the observed amount of dissolved metal to the theoretical amount predicted from Faraday’s law. In ECM, the current efficiency curve relates the dissolution rate of the anode material and the current density. Accurate measurement of the current efficiency curve is the basis for anode shape prediction and cathode tool design. However, in conventional measurement methods, the phenomenon of edge stray corrosion introduces significant measurement errors. Improving the current efficiency is thus a challenging task for any electrophysical or electrochemical machining process. To improve the measurement accuracy, this paper proposes a current efficiency curve measurement with a casing-type anode. In the proposed measurement method, the anode is designed in two parts: the mandril and the casing. The edge stray corrosion effect is mainly concentrated on the casing, and only the current distribution on the mandril is considered in the calculation of current efficiency. The measurement simulations of the conventional and the proposed methods were carried out. The simulation results show that the casing-type method significantly improves the accuracy of current efficiency measurements, and the current efficiency curve of 304SS was obtained.

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Multiphysics Simulation of Electrochemical Machining Process for Three-Dimensional Compressor Blade

Cited by 82 publications

References 10 publications

Mechanism of 6061 Aluminium Material Erosion in USEMM

Mechanism of 6061 Aluminium Material Erosion in USEMM

Experimental Study on the Influence of Tool Electrode Material on Electrochemical Micromachining of 304 Stainless Steel

A Study of Precision Current Efficiency Curve Measurement with a Casing-Type Anode

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