Real-time vision-assisted electrochemical machining with constant inter-electrode gap

2021 ◽  
Vol 71 ◽  
pp. 384-397
Author(s):  
Jingtao Wang ◽  
Zhengyang Xu ◽  
Jia Liu ◽  
Xiaojun Tang
Keyword(s):  
Real Time ◽  
Electrochemical Machining ◽  
Electrode Gap

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.

scholarly journals Approach to setting the mode parameters in combined electro-erosive - electrochemical processing during piercing the deep holes of small diameter

2021 ◽  
Vol 2131 (4) ◽  
pp. 042012
Author(s):  
S Vasilevskaya ◽  
Yu Nikitin
Keyword(s):  
Electrochemical Machining ◽  
Small Diameter ◽  
Electrode Gap ◽  
Electrochemical Processing ◽  
Processed Material

Abstract The article considers the problem of forming the deep holes of small diameter by using the combined electro-erosive and electrochemical machining based on the electrochemical and electro-erosive processes. The approach to setting the mode parameters during piercing the deep holes with a diameter of less than 1 mm is suggested. The approach takes into consideration the influence of hydrodynamic losses in the inter-electrode gap on the limitation of the mode parameters of the electrochemical and electro-erosive components in the combined processing. It also takes into account the interrelation between the magnitude of the inter-electrode gap and the linear velocities of the removal of the processed material in each of the components during the combined processing. The validity of the approach to setting the mode parameters in the combined electro-erosive -electrochemical processing during piercing the deep holes with a diameter from 0.3 mm to 1 mm in the range of the inter-electrode gap from 0.025 mm to 1 mm is experimentally confirmed.

Experimental Investigation of Cut Profile in the Electrochemical Drilling of Titanium Alloy

2018 ◽  
Vol 777 ◽  
pp. 327-332
Author(s):  
Ornsurang Netprasert ◽  
Noppakao Chimyo ◽  
Suphaphich Phimphun ◽  
Jantakarn Sukjan ◽  
Viboon Tangwarodomnukun ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Applied Voltage ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Experimental Result ◽  
Drilling Process ◽  
Electrode Gap ◽  
Electrochemical Drilling ◽  
Cut Quality

Electrochemical machining process is an advanced material removal technique offering high precision and introducing no heat damage to the work material. The shape and size of machined area are highly dependent on some process parameters such as voltage, electrolyte and inter-electrode gap. To further enable a more insight into the process performance, this paper investigates the influences of applied voltage, electrolyte concentration and inter-electrode gap on the shape and sizes of hole produced by the electrochemical drilling process. Titanium alloy (Ti-6Al-4V) was used as a work sample in this study as it has been extensively used in many advanced applications. The experimental result indicated that the use of high voltage and high electrolyte concentration can enlarge and deepen hole in the workpiece, while the inter-electrode gap provided less effect to the hole features. The maximum hole depth can reach 300 μm within 60 seconds when the applied voltage of 30 V, the inter-electrode gap of 10 μm and the electrolyte concentration of 10%wt were used. However, with this setup, the obtained cut profile became a non-uniform V-shaped hole. The use of lower voltage was instead recommended to yield a better cut quality with U-shaped profile.

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.

Fundamental Experimental Study on Numerical-Control Electrochemical Finish Machining for Integral Impeller Blade

2011 ◽  
Vol 55-57 ◽  
pp. 1275-1280 ◽  
Author(s):  
Jian Min Wu ◽  
Jia Wen Xu
Keyword(s):  
Electrochemical Machining ◽  
Normal Direction ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Blade Surface ◽  
Electrode Gap ◽  
Impeller Blade ◽  
Finish Machining

While the surface of integral impeller blade was electrochemically machined, cathode cannot rotate in accordance with other movement axes, which results in nonuniformity in velocity of electrolyte and normal direction of the machining blade surface, thereby causing inaccuracy in the machined blade surface. In order to solve this problem, the shaping law was studied in Electrochemical Finish Machining. Then relative positions between cathode slot and blade surface were analyzed during the process of Electrochemical Machining (ECM). Three parameters, namely feed direction, feed velocity and initial machining inter-electrode gap, were adjusted to conduct the fundamental experiments when direction of cathode slot was changed. Afterwards machining accuracy as well as surface quality of workpiece was analyzed. Finally according to experimental results, direction of cathode slot was determined practically in electrochemical machining process and the integral impeller blades meeting the requirement were electrochemically machined.

Real-Time Electrical Characterization of Dielectrophoretic Assembly of Multi-Walled Carbon Nanotubes

2007 ◽  
Vol 1057 ◽  
Author(s):  
Libao An ◽  
Craig Friedrich
Keyword(s):  
Carbon Nanotubes ◽  
Real Time ◽  
Electrical Characterization ◽  
Electrode Gap ◽  
Monitoring Method ◽  
Impedance Model ◽  
Multi Walled Carbon Nanotubes ◽  
Walled Carbon Nanotubes ◽  
Simultaneous Variation

ABSTRACTThis paper reports on a real-time monitoring method for the assembly of a small number of metallic carbon nanotubes (CNTs) by dielectrophoresis (DEP). A time-varying impedance model of the electrode gap was developed to evaluate the number of CNTs which span the gap by measuring the simultaneous variation of gap impedance during the DEP process. Sudden decreases of gap impedance signals were detected during the DEP assembly of multi-walled carbon nanotubes (MWNTs) corresponding to assembly of single or multiple tubes across the gap. The method reduces the requirement of scanning electron microscopy (SEM) inspection and could help automate DEP assembly of CNTs.

Electrochemical machining of 20MnCr5 alloy steel with magnetic flux assisted vibrating tool

2015 ◽  
Vol 231 (10) ◽  
pp. 1956-1965 ◽  
Author(s):  
S Ayyappan ◽  
K Sivakumar ◽  
M Kalaimathi
Keyword(s):  
Magnetic Flux ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Full Potential ◽  
Hybrid Technique ◽  
Machining Performance ◽  
Electrode Gap ◽  
Contour Plots ◽  
Control Of Parameters

Utilization of full potential of electrochemical machining (ECM) is not yet achieved because of its lack of accuracy, difficulty in proper tool design and control of parameters. The enhancement of performance of ECM is still a subject of concern in this modern manufacturing world. In this work, low frequency vibrating tool assisted by a magnetic flux was used as an efficient hybrid technique in ECM for improving material removal rate (MRR) and surface roughness (Ra). This paper presents a development of mathematical model correlating MRR and Ra with machining conditions such as voltage, electrolyte concentration, and inter-electrode gap. The significance of ECM process parameters has been investigated using contour plots. The inter-electrode gap (IEG) is considered slightly higher than the maximum tool amplitude that otherwise leads to tool damage. Results indicate that magnetic flux-assisted vibrating tool increases the MRR from 10% to 96%. A magnetic flux-assisted vibrating tool in ECM facilitates and drives out the sludge in the IEG to improve the machining performance. MRR is enhanced due to the movement of ions triggered by magnetic flux, which assures an increase in anodic current. A slight increase in Ra was also noted in comparison to machining with aqueous NaCl electrolyte alone.

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