scholarly journals Design and optimization of electrolyte flow fields in electrochemical machining of cross-channel array with tool vibration

2021 ◽  
Author(s):  
Yan Liu ◽  
Jia Liu ◽  
Di Zhu ◽  
Hao Wang
Keyword(s):  
Electrochemical Machining ◽  
Flow Fields ◽  
Electrolyte Flow ◽  
Tool Vibration ◽  
Design And Optimization

scholarly journals Research on Stagger Coupling Mode of Pulse Duration and Tool Vibration in Electrochemical Machining

2018 ◽  
Vol 8 (8) ◽  
pp. 1296 ◽  
Author(s):  
Xiaochen Jiang ◽  
Jia Liu ◽  
Di Zhu ◽  
Mingming Wang ◽  
Ningsong Qu
Keyword(s):  
Pulse Duration ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Tool Vibration ◽  
Coupling Mode ◽  
Machining Localization ◽  
Electrolysis Products ◽  
Gas Void Fraction

Tuning the coupling of pulse duration and tool vibration in electrochemical machining (PVECM) is an effective method to improve machining accuracy and surface quality. In general, the pulse is set at the same frequency as the tool vibration, and a symmetrical distribution is attained at the minimum inter-electrode gap. To analyse the characteristics of the electrolyte fluid flow and of the electrolysis products in the oscillating inter-electrode gap, a dynamic simulation of the PVECM process was carried out. The simulation results indicated that the electrolyte pressure and gas void fraction when the pulse arrived as the inter-electrode gap was narrowing clearly differed from those when the inter-electrode gap was expanding. Therefore, in addition to the traditional symmetry coupling mode, two other coupling modes called the pre-position and the post-position coupling modes are proposed which use a pulse either just before or just after the minimum inter-electrode gap. Comparative experiments involving the feed rate and machining localization were carried out to evaluate the influence of the three coupling modes. In addition, current waveforms were recorded to analyse the differences between the three coupling modes. The results revealed that the highest feed rate and the best machining localization were achieved by using the pre-position coupling mode.

Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow

2015 ◽  
Vol 80 (1-4) ◽  
pp. 637-645 ◽  
Author(s):  
Dong Zhu ◽  
Juchen Zhang ◽  
Kuanglei Zhang ◽  
Jia Liu ◽  
Zhu Chen ◽  
...  
Keyword(s):  
Electrochemical Machining ◽  
Electrolyte Flow

CFD ANALYSIS OF ELECTROLYTE FLOW IN ELECTROCHEMICAL MACHINING

2019 ◽  
Vol 17 (1) ◽  
pp. 203-214
Author(s):  
Biswesh Ranjan Acharya ◽  
Sukanta Nayak ◽  
Amrit Mallick
Keyword(s):  
Electrochemical Machining ◽  
Cfd Analysis ◽  
Electrolyte Flow

Experimental Flow Visualization Study in a Trapezoidal Duct With Impingement Jets and Cross Flow Near the Leading Edge

2010 ◽  
Author(s):  
Haiyong Liu ◽  
Songling Liu ◽  
Hongfu Qiang ◽  
Cunliang Liu
Keyword(s):  
Film Cooling ◽  
Cross Flow ◽  
Side Wall ◽  
Leading Edge ◽  
Flow Fields ◽  
Flow Structures ◽  
Internal Cooling ◽  
Design And Optimization ◽  
Target Wall ◽  
Cooling Hole

An enlarged model of trapezoidal duct in leading-edge with impingement jets, swirl, cross flow and effusion was built up. Experiments were performed to measure flow fields in the confined passage and exit holes on one of its side walls. A row of staggered circular impingement holes were arranged on the opposite side wall. Cross flow and effusion flow was induced in the channel by the outflow of exit hole and film cooling hole, which were oriented on one end wall and bottom wall of the passage. Detailed flow structures were measured for two impingement angles of 35° and 45° with 6 combinations of out flow ratios. Results showed that the small jets impinged the target wall effectively while the large jets contributed to inducing and impelling a strong counter-clockwise vortex in the upper part of the passage. Cross flow had significant effect on the flow structures in the passage and exit holes. It deflected the jets, enhanced swirl and deteriorated side exit conditions. Impingement angle also had important influence on flow fields and its effect revealed more evidently with cross flow. Within the present test conditions, the mass flow rates and outflow positions of film cooling holes had no distinct effect on the main flow structures. These data were helpful for the design and optimization of internal cooling structures in gas turbine airfoils.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

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