Research on Multi-Physics Coupling Simulation for the Pulse Electrochemical Machining of Holes with Tube Electrodes

Li, Zhaolong; Cao, Bisong; Dai, Ye

doi:10.3390/mi12080950

Cited by 11 publications

(5 citation statements)

References 22 publications

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“…3. The theoretical analysis of simulation modeling is based on the following assumptions:(1) The conductivity of the tool cathode and the workpiece anode is much larger than that of the electrolyte, and both the cathode surface and the workpiece surface are equipotential surfaces, (2) Since the machining area is much larger than the machining gap, the boundary effect can be neglected [25][26]. The yellow area represents the machined workpiece and the gray area represents the robot end cathode tool.…”

Section: Theoretical Model Analysis Of Machining Gap Controlmentioning

confidence: 99%

Gap control method for electrochemical milling machining under robot trajectory error perturbation

Yu,

Fang,

Jiang

et al. 2023

Preprint

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Industrial robots have great potential for highly flexible manufacturing of complex and difficult-to-machine parts due to their advantages of high flexibility, high dexterity, and strong sensing ability. Also, electrochemical milling machining methods have important application prospects in the efficient and precise machining of difficult-to-cut machined part materials. Robotic electrochemical milling is now becoming a hot spot in the research of new electrochemical machining technology. However, the weak stiffness and low precision of industrial robots themselves will produce errors in the normal gap in electrochemical milling. The inter-electrode gap directly affects the process performance of electrochemical machining in terms of machining accuracy and surface quality. To reduce the effect of robot trajectory error perturbations on the interpolar gap, real-time control of the machining gap is required. In this paper, we propose a normal motion error correction control system that extends the seventh axis. Its gap control strategy is based on real-time measurement of the machining current, the current fluctuation is converted into a normal error compensation amount, and the end-effector completes the error amount of the machining gap compensation. The response performance of this gap control system was simulated and analyzed, and an experimental platform was designed and built. Finally, to verify the effectiveness of the machining gap control servo system, experiments were carried out on the machining of flat workpieces. The experimental results surface that the method can effectively control the IEG fluctuation in robotic electrochemical milling within a small range, which ultimately improves the machining accuracy and surface quality of the parts.

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Section: Theoretical Model Analysis Of Machining Gap Controlmentioning

confidence: 99%

Gap control method for electrochemical milling machining under robot trajectory error perturbation

Yu,

Fang,

Jiang

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…According to the Reynolds number, the electrolyte is in a turbulent state (R e >> 2300) [33]. Considering the influence of bubbles, the RANS k-ε turbulence model is suitable for the current situation and is adopted to simulate the flow field in this study [34].…”

Section: Flow Field Modelingmentioning

confidence: 99%

Multi-Physics Coupling Modeling and Experimental Investigation of Vibration-Assisted Blisk Channel ECM

et al. 2021

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Due to its advantages of good surface quality and not being affected by material hardness, electrochemical machining (ECM) is suitable for the machining of blisk, which is known for its hard-to-machine materials and complex shapes. However, because of the unstable processing and low machining quality, conventional linear feeding blisk ECM has difficulty in obtaining a complex structure. To settle this problem, the vibration-assisted ECM method is introduced to machine blisk channels in this paper. To analyze the influence of vibration on the process of ECM, a two-phase flow field model is established based on the RANS k-ε turbulence model, which is suitable for narrow flow field and high flow velocity. The model is coupled with the electric field, the flow field, and the temperature field to form a multi-physics field coupling model. In addition, dynamic simulation is carried out on account of the multi-physics field coupling model and comparative experiments are conducted using the self-developed ECM machine tool. While a shortcut appeared in the contrast experiment, machining with vibration-assisted channel ECM achieved fine machining stability and surface quality. The workpiece obtained by vibration-assisted channel ECM has three narrow and straight channels, with a width of less than 3 mm, an aspect ratio of more than 8, and an average surface roughness Ra in the hub of 0.327 μm. Compared with experimental data, the maximum relative errors of simulation are only 1.05% in channel width and 8.11% in machining current, which indicates that the multi-physics field coupling model is close to machining reality.

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“…Simulation results show that pulsed tube electrode ECM can improve temperature distribution. Temperature rise is mainly affected by electrical parameters such as duty cycle [17]. By constructing a multiphysics model and quasi steady state shortcut (QSSSC) method, the temperature field distribution in pulse ECM (PECM) processing has been successfully modeled [18].…”

Section: Introductionmentioning

confidence: 99%

Low Temperature Interface Modification: Electrochemical Dissolution Mechanism of Typical Iron and Nickel Base Alloys

Lu,

Xu,

Geng

2024

J. Electrochem. Sci. Technol

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Due to its unique advantages, electrochemical machining (ECM) is playing an increasingly significant role in the manufacture of difficult-to-machine materials. Most of the current ECM research is conducted at room temperature, with studies on ECM in a cryogenic environment not having been reported to date. This study is focused on the electrochemical dissolution characteristics of typical iron and nickel base alloys in NaNO<sub>3</sub> solution at low temperature (–10°C). The polarization behaviors and passive film properties were studied by various electrochemical test methods. The results indicated that a higher voltage is required for decomposition and more pronounced pitting of their structures occurs in the passive zone in a cryogenic environment. A more in-depth study of the composition and structure of the passive films by X-ray photoelectron spectroscopy and electrochemical impedance spectroscopy showed that the passive films of the alloys are modified at low temperature, and their capacitance characteristics are more prominent, which makes corrosion of the alloys more likely to occur uniformly. These modified passive films have a huge impact on the surface morphologies of the alloys, with non-uniform corrosion suppressed and an improvement in their surface finish, indicating that lowering the temperature improves the localization of ECM. Together with the cryogenic impact of electron energy state compression, the accuracy of ECM can be further improved.

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Research on Multi-Physics Coupling Simulation for the Pulse Electrochemical Machining of Holes with Tube Electrodes

Cited by 11 publications

References 22 publications

Gap control method for electrochemical milling machining under robot trajectory error perturbation

Gap control method for electrochemical milling machining under robot trajectory error perturbation

Multi-Physics Coupling Modeling and Experimental Investigation of Vibration-Assisted Blisk Channel ECM

Low Temperature Interface Modification: Electrochemical Dissolution Mechanism of Typical Iron and Nickel Base Alloys

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