scholarly journals Extension of the Process Window in Laser Chemical Machining by Temperature-Dependent Reduction of the Electrolyte Viscosity

2021 ◽  
Author(s):  
Marcel Simons ◽  
Tim Radel ◽  
Frank Vollertsen
Keyword(s):  
Sulfuric Acid ◽  
Chemical Process ◽  
Machining Process ◽  
Shielding Effect ◽  
Process Window ◽  
Experimental Investigations ◽  
Temperature Dependent ◽  
Local Overheating ◽  
Boiling Process ◽  
Titanium Grade

AbstractThe laser chemical process is a material-removing machining process in the micro range. The process is based on a laser-assisted etching process between an electrolyte and a metallic workpiece. Local overheating causes a laser-induced electrolyte boiling process, which limits the laser chemical process window. In order to reduce the laser-induced electrolyte boiling process and thus expand the process window, the laser chemical process is carried out at different electrolyte start temperatures and thus different electrolyte viscosities and surface tensions. The experimental investigations were carried out on Titanium Grade 1 with the electrolytes phosphoric acid and sulfuric acid at different electrolyte temperatures and laser powers to determine the limits of the process window by evaluating the properties of the removal cavities. As a result, the process window is extended at lower electrolyte viscosities. Thereby, the electrolyte viscosities have no influence on the geometric shape of the removal. The extension of the process window is attributed to the fact that a reduction in electrolyte viscosity results in a less pronounced formation of the boiling process, the bubble diameters decrease, and the shielding effect of the bubbles is reduced.

Theoretical and experimental investigations of local overheating at particle contacts in spark plasma sintering

2017 ◽  
Vol 321 ◽  
pp. 458-470 ◽  
Author(s):  
Christophe Collard ◽  
Zofia Trzaska ◽  
Lise Durand ◽  
Jean-Marc Chaix ◽  
Jean-Philippe Monchoux
Keyword(s):  
Spark Plasma Sintering ◽  
Experimental Investigations ◽  
Local Overheating ◽  
Plasma Sintering ◽  
Spark Plasma

Temperature Field Simulation of Anode Erosion in Electric Discharge Machining

2010 ◽  
Vol 455 ◽  
pp. 345-349
Author(s):  
B.C. Xie ◽  
Zhen Long Wang ◽  
Yu Kui Wang ◽  
Jing Zhi Cui
Keyword(s):  
Temperature Field ◽  
Electric Discharge ◽  
Material Removal ◽  
Machining Process ◽  
Model Parameters ◽  
Temperature Dependent ◽  
Electric Discharge Machining ◽  
Field Simulation ◽  
Simulation And Experiment ◽  
Anode Erosion

In this paper, a thermo-physical model of the electric discharge machining process using finite element method is presented. In this model, parameters such as convection, the latent heat and the thermal properties based on temperature dependent etc. are studied to predict the temperature distribution in the workpiece. The temperature field simulation and experiment were carried out by adopting parameters through optimum pulse curve, and amending the effects of recast layer, the simulation results amended shows a better agreement with experimental results, indicating a theoretical foundation for mechanism of material removal in EDM machining.

Machining Characteristics Estimation in WEDM Process While Machining Titanium Grade-2 Material Using ANN

2020 ◽  
Author(s):  
Prathik Jain Sudhir ◽  
Ravindra Holalu Venkatadas ◽  
Ugrasen Gonchikar
Keyword(s):  
Process Parameters ◽  
Machining Process ◽  
Electrode Wear ◽  
Training Set ◽  
Hard Materials ◽  
Titanium Grade ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Machining Characteristics

Abstract Wire Electrical Discharge Machining (WEDM) provides an effective solution for machining hard materials with intricate shapes. WEDM is a specialized thermal machining process is capable to accurately machining parts of hard materials with complex shapes. However, selection of process parameters for obtaining higher machining efficiency or accuracy in wire EDM is still not fully solved, even with the most up-to-date CNC WED machine. The study presents the machining of Titanium grade 2 material using L’16 Orthogonal Array (OA). The process parameters considered for the present work are pulse on time, pulse off time, current, bed speed, voltage and flush rate. Among these process parameters voltage and flush rate were kept constant and the other four parameters were varied for the machining. Molybdenum wire of 0.18mm is used as the electrode material. Titanium is used in engine applications such as rotors, compressor blades, hydraulic system components and nacelles. Its application can also be found in critical jet engine rotating and airframes components in aircraft industries. Firstly optimization of the process parameters was done to know the effect of most influencing parameters on machining characteristics viz., Surface Roughness (SR) and Electrode Wear (EW). Then the simpler functional relationship plots were established between the parameters to know the possible information about the SR and EW. This simpler method of analysis does not provide the information on the status of the material and electrode. Hence more sophisticated method of analysis was used viz., Artificial Neural Network (ANN) for the estimation of the experimental values. SR and EW parameters prediction was carried out successfully for 50%, 60% and 70% of the training set for titanium material using ANN. Among the selected percentage data, at 70% training set showed remarkable similarities with the measured value then at 50% and 60%.

scholarly journals Wastewater Minimization in Indirect Electrochemical Synthesis of Phenylacetaldehyde

2002 ◽  
Vol 2 ◽  
pp. 48-52 ◽  
Author(s):  
Zhirong Sun ◽  
Xiang Hu ◽  
Ding Zhou
Keyword(s):  
Sulfuric Acid ◽  
Current Efficiency ◽  
Electrochemical Oxidation ◽  
Acid Concentration ◽  
Electrochemical Synthesis ◽  
Chemical Process ◽  
Sulfuric Acid Concentration ◽  
High Yield ◽  
High Current ◽  
High Current Efficiency

Wastewater minimization in phenylacetaldehyde production by using indirect electrochemical oxidation of phenylethane instead of the seriously polluting traditional chemical process is described in this paper. Results show that high current efficiency of Mn(III) and high yield of phenylacetaldehyde can be obtained at the same sulfuric acid concentration (60%). The electrolytic mediator can be recycled and there will be no waste discharged.

Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V

2011 ◽  
Vol 418-420 ◽  
pp. 1478-1481 ◽  
Author(s):  
Manoj Modi ◽  
Gopal Agarwal
Keyword(s):  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Hybrid Machining ◽  
Hard Materials ◽  
Hybrid Machining Process ◽  
Pulse On Time

Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.

Analysis of Cutting Technologies for Lightweight Frame Components

2006 ◽  
Vol 10 ◽  
pp. 121-132 ◽  
Author(s):  
Klaus Weinert ◽  
Sven Grünert ◽  
Michael Kersting
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Thermal Stresses ◽  
Machining Process ◽  
Frame Structure ◽  
Experimental Investigations ◽  
Promising Alternative ◽  
Thin Walled ◽  
Process Strategy ◽  
Conventional Drilling

Most technical components applied in industrial practice are subjected to metal cutting operations during their production process. However, this leads to undesirable thermal and mechanical loads affecting the machined workpiece, which can result in an impairment of its serviceability. Due to their small wall thickness lightweight hollow profiles are highly susceptible to the inevitable machining loads and thermal stresses during drilling processes. For the virtual optimization of the machining process and in order to ensure a suitable process strategy, a finite element simulation of cutting operations for thin-walled light metal profiles is conducted. Due to the flexibility within creating drill holes of different diameters without tool changes circular milling represents a promising alternative to the application of conventional drilling tools for variable process strategies to handle batch sizes down to one piece efficiently. Hence, this article gives an insight into the investigations regarding the modeling concepts of the mechanical and thermal loads induced into the thin-walled lightweight frame structure during the circular milling process. Furthermore, process reliability aspects as well as the correlation of the calculated and the measured results will be discussed on the basis of experimental investigations. Finally, this article compares Finite Element Analysis aspects of circular milling processes with conventional drilling processes.

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