Study of the electrolyte flow at narrow openings during electrochemical machining

Klink, Andreas; Heidemanns, L.; Rommes, Bob

doi:10.1016/j.cirp.2020.04.075

Cited by 19 publications

(6 citation statements)

References 13 publications

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“…Achieving a uniform and stable distribution of electrolyte ow within the ECM processing gap region is essential for the successful operation of spline axial ECM [21]. High-speed electrolyte ow serves the crucial role of e ciently removing by-products generated within the narrow ECM processing gap region, thereby preventing issues like electrolyte starvation and cavitation, which can potentially lead to short circuits.…”

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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“…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: 98%

“…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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“…16 Klink et al found that when an electrolyte enters the processing area through a narrow gap, cavitation can easily occur near the entrance. 17 Zhu et al proposed a new flow field structure for ECTr that improved the machining speed to 4.00 mm/min and reduced the blade surface roughness. 18 Furthermore, Burger et al determined that low current densities yield inhomogeneous electrochemical dissolution of the material and achieved high surface qualities by employing homogenous electrochemical dissolution, which was realized using high current densities.…”

Section: Introductionmentioning

confidence: 99%

Research on depth control of machining trace in electrochemical trepanning

Zhu

Zhang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrochemical trepanning (ECTr) is a highly effective and economic manufacturing technology for machining difficult-to-cut metal materials that are often used in aeroengine components. Integral structural components such as blisks, diffusers, etc. are composed of hubs and blades. In continuous ECTr, machining trace stems from on the hub between adjacent blades. The depth of machining trace significantly influences the surface integrity of the integrated components, even causes the scrapping of the workpiece. In order to solve the problem of machining trace in ECTr, a cathode design method based on the relation between cathode profile and electric field distribution is proposed in this study, the edge of the cathode that affects the machining trace is chamfered. A electric field model of ECTr is established and dynamic electric field simulation of ECTr for cathodes with different chamfered edges is performed. The electric field intensity distribution at the cathode edge and the forming profile of the hub are compared. The simulation results show that optimal chamfering parameters can improve the machining trace. Subsequently, a group of cathodes with different chamfered edge is designed, and corresponding ECTr experiments are conducted. The optimal chamfering parameters are determined (α = 5°, b = 2 mm), the depth of the machining trace is reduced from 0.370 mm to 0.122 mm, the surface flatness is significantly improved. Overall, this depth control method of machining trace is verified effectively.

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Study of the electrolyte flow at narrow openings during electrochemical machining

Cited by 19 publications

References 13 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

Simulation of electrolyte behaviour of industrial electrochemical machining

Research on depth control of machining trace in electrochemical trepanning

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