Workpiece reciprocating movement aided wire electrochemical machining using a tube electrode with an array of holes

Yang, Tao; Zeng, Yongbin; Hang, Yusen

doi:10.1016/j.jmatprotec.2019.04.044

Cited by 15 publications

(5 citation statements)

References 18 publications

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“…However, the top and bottom sides of the slit have quite different widths. In another approach, a linear metal tube with array holes replaces the conventional metal wire as the tool cathode, with electrolyte being injected directly into the machining gap through these holes to wash out electrolytic products [21]. A feed rate of 5 µm/s for a 10-mm-thick 304 stainless steel workpiece can be achieved with this technique.…”

Section: Introductionmentioning

confidence: 99%

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Yang

Fang

Hang

et al. 2021

Int J Adv Manuf Technol

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Electrochemical cutting using tube electrode with inclined holes is a machining method that directly and obliquely injects electrolyte into the machining gap through inclined jet-ow holes on the sidewall of a tube electrode, allowing the electrochemical cutting of a workpiece. To improve the machining e ciency and accuracy of this cutting technique, a method of workpiece vibration in feed direction assisted electrochemical cutting is proposed in which workpiece vibration along the feed direction rapidly and periodically changes the machining gap. The near-instantaneous increases in the machining gap promotes the waste electrolyte containing electrolytic products to ow down the machining gap. At the same time, the electrochemical reaction time under the non-uniform ow eld caused by the inclined downward injection of electrolyte is reduced. The ow eld simulation of electrolyte in machining gap indicates that the near-instantaneous increases in the machining gap can improve the ow velocity of electrolyte. Experiment demonstrates that the average feed rate can be increased by 50% and the machining e ciency is superior to that of electrochemical cutting assisted by workpiece non-vibration in feed direction. The difference between the upper and lower slit widths is reduced and the machining accuracy is improved. The effect of the vibrational amplitude and frequency on the machining result is also investigated. Finally, an array slice structure is fabricated on a stainless steel block with a crosssection of 10 mm × 10 mm at average feed rate of 6 mm/s using a vibrational amplitude and frequency of 0.1 mm and 1.5 Hz, respectively.

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Section: Introductionmentioning

confidence: 99%

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Yang

Fang

Hang

et al. 2021

Int J Adv Manuf Technol

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“…The other processes are driven by drag action from an assisted slippage between the wire electrode and the workpiece. A linear vibration 15 and reciprocating movement 16,17 along the axial direction of a wire electrode have been experimentally verified to be beneficial for the mass transfer process and machining process stability. Moreover, several novel electrodes such as a ribbed wire 18 and surface-textured wire 19,20 were developed to intensify this action.…”

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confidence: 99%

Pulse-Current Wire Electrochemical Machining with Axial Electrolyte Flushing along a Rotating Helical Wire Tool

Fang¹,

Han²,

Mi³

et al. 2020

J. Electrochem. Soc.

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The production of economical turbine slots with high efficiency and good surface integrity is a common concern in aviation manufacturing. State-of-the-art wire electrochemical machining (WECM) cannot afford the efficient precision machining of macro structures with thicknesses over tens of millimeters. This work investigated a pulse-current WECM process combining high-speed rotation of a helical wire tool and axial electrolyte flushing. Theoretical analysis and experimental results indicate that pulse frequency has a significant influence on the machining of thick specimens. The pulse-current charging process was prolonged with the increase in workpiece thickness, and it took up the majority of the pulse-on time at a pulse frequency over 50 kHz when the workpiece thickness reached 15 mm. The maximum feed rate first increased with pulse frequency, and then decreased from 20 to 100 kHz when a 20-mm-thick workpiece was being cut. Subsequently, the processes of electrolyte refreshment and product removal were maximized when the helical wire electrode rotated clockwise, and axial electrolyte flushing was applied. Finally, a fir-tree slot of 20 mm thickness with good dimensional consistency and good surface quality was stably processed at a rate of 5 μm s −1 .

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“…Figure40. WECM scheme (b) using rotating helical electrode (a)[121]. "Reprinted/adapted with permission from Ref [121]…”

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confidence: 99%

“…Wire ET scheme (a), scheme of the machining technology of fir tree slots consisting of WEDM pre-slotting (b) and Wire ET finishing (c)[126]. "Reprinted/adapted with permission from Ref [121]…”

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The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

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Workpiece reciprocating movement aided wire electrochemical machining using a tube electrode with an array of holes

Cited by 15 publications

References 18 publications

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes

Pulse-Current Wire Electrochemical Machining with Axial Electrolyte Flushing along a Rotating Helical Wire Tool

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

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