scholarly journals Multiphysics Simulation of the Material Removal in Jet Electrochemical Machining

Procedia CIRP ◽  
2015 ◽  
Vol 31 ◽  
pp. 197-202 ◽  
Author(s):  
Matthias Hackert-Oschätzchen ◽  
Raphael Paul ◽  
Michael Kowalick ◽  
André Martin ◽  
Gunnar Meichsner ◽  
...  
Keyword(s):  
Material Removal ◽  
Electrochemical Machining ◽  
Multiphysics Simulation ◽  
Jet Electrochemical Machining

scholarly journals New insights on manipulating the material removal characteristics of Jet-Electrochemical machining through nozzle design

2021 ◽  
Author(s):  
Thomas Kendall ◽  
Carl Diver ◽  
David Gillen ◽  
Paulo Bartolo
Keyword(s):  
Material Removal ◽  
Electrochemical Machining ◽  
Nozzle Geometry ◽  
Depth Of Cut ◽  
Nozzle Design ◽  
Physical Experiments ◽  
Nozzle Hole ◽  
The University ◽  
University Of Manchester ◽  
Jet Electrochemical Machining

AbstractJet-Electrochemical machining (Jet-ECM) is a novel variation of traditional electrochemical machining in which electrically conductive material is removed through anodic dissolution by means of a fine jet of electrolyte. In this study, the effect of nozzle geometry on material removal characteristics are investigated through physical experiments performed on a Jet-ECM system under development at the university of Manchester. A total of 8 nozzles with holes encompassing converging, diverging and rounded features are studied at flow rates between 0.125 and 0.225 l/min. The results show that the nozzle hole geometry has a significant effect on the machined profile produced due to variations in flow velocity, pressure, and electric current distribution with converging hole nozzles providing an increased depth of cut than the symmetrical cylindrical channel by up to 9.7%. A 2D Star CCM+ simulation is also proposed, and numerical results developed and compared with experimental ones to investigate the feasibility of using simulation to develop future nozzle designs. The simulated results show good profile comparison to the experimental results, however, the model needs developing to improve the process repeatability for future use in nozzle design.

scholarly journals 3D Multiphysics Simulation of Jet Electrochemical Machining of Intersecting Line Removals

Procedia CIRP ◽  
2019 ◽  
Vol 82 ◽  
pp. 196-201
Author(s):  
Raphael Paul ◽  
Matthias Hackert-Oschätzchen ◽  
Igor Danilov ◽  
Matin Yahyavi Zanjani ◽  
Andreas Schubert
Keyword(s):  
Electrochemical Machining ◽  
Multiphysics Simulation ◽  
Jet Electrochemical Machining

scholarly journals The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 404 ◽  
Author(s):  
Xinmin Zhang ◽  
Xudong Song ◽  
Pingmei Ming ◽  
Xinchao Li ◽  
Yongbin Zeng ◽  
...  
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Horizontal Orientation ◽  
Jet Electrochemical Machining ◽  
Machining Characteristics ◽  
Machining Localization ◽  
Vertical Jet

Jet electrochemical machining (Jet-ECM) is a significant prospective electrochemical machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet machining, and the effect of jet orientations on machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of machining localization and a reduction of MMR for horizontal jet electrochemical machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve machining accuracy.

scholarly journals Insights on the Influence of Surface Chemistry and Rim Zone Microstructure of 42CrMo4 on the Efficiency of ECM

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2132
Author(s):  
Alexander Schupp ◽  
Oliver Beyss ◽  
Bob Rommes ◽  
Andreas Klink ◽  
Daniela Zander
Keyword(s):  
Mixed Oxide ◽  
Photoelectron Spectroscopy ◽  
Inductively Coupled Plasma ◽  
Material Removal ◽  
Chemical Elements ◽  
Nitrate Solution ◽  
Electrochemical Machining ◽  
Process Efficiency ◽  
Negative Effect ◽  
Sodium Nitrate Solution

The electrochemical machining (ECM) of 42CrMo4 steel in sodium nitrate solution is mechanistically characterized by transpassive material dissolution and the formation of a Fe3−xO4 mixed oxide at the surface. It is assumed that the efficiency of material removal during ECM depends on the structure and composition of this oxide layer as well as on the microstructure of the material. Therefore, 42CrMo4 in different microstructures (ferritic–pearlitic and martensitic) was subjected to two ECM processes with current densities of about 20 A/cm2 and 34 A/cm2, respectively. The composition of the process electrolyte was analyzed via mass spectrometry with inductively coupled plasma in order to obtain information on the efficiency of material removal and the reaction mechanisms. This was followed by an X-ray photoelectron spectroscopy analysis to detect the chemical composition and the binding states of chemical elements in the oxide formed during ECM. In summary, it has been demonstrated that the efficiency of material removal in both ECM processes is about 5–10% higher for martensitic 42CrMo4 than for ferritic–pearlitic 42CrMo4. This is on one hand attributed to the presence of the cementite phase at ferritic–pearlitic 42CrMo4, which promotes oxygen evolution and therefore has a negative effect on the material removal efficiency. On the other hand, it is assumed that an increasing proportion of Fe2O3 in the mixed oxide leads to an increase in the process efficiency.

The Law Technology Study and the Mechanism Analysis of Small-Size Machined by Electro Jet Machining

2012 ◽  
Vol 499 ◽  
pp. 179-185
Author(s):  
Zhi Bo Yin ◽  
Fu Yuan Li ◽  
C.X. Wang
Keyword(s):  
Duty Cycle ◽  
Material Removal ◽  
Electrochemical Machining ◽  
Corrosion Mechanism ◽  
Mechanism Analysis ◽  
Technology Study ◽  
Original Experiment ◽  
The Law ◽  
Faraday Law ◽  
Main Factor

In order to research the Law technology and the equipment performance of Electro Jet, The institute developed an electro jet machine. Through a large number of experiments on this machine, the author concluded its process law and analysis the corrosion mechanism to the removed process. The results show that, duty cycle and frequency have a certain effect on the machine accuracy, and duty cycle is the main factor of aperture morphology. When duty cycle varies from 30%~40%, the stray corrosion is less. Frequency affects the depth seriously, based on the original experiment, voltage, duty cycle. Frequencies were not interactive within the scope of the study. The corrosion of anodic workpiece satisfies Faraday law by the study of material removal mechanism. Current efficiency is less than 1, and it’s 40%~60%.current density is 2~4.5A/mm2, that is larger than ordinary electrochemical machining.

Effect of valency on material removal rate in electrochemical machining of aluminium

2008 ◽  
Vol 202 (1-3) ◽  
pp. 398-401 ◽  
Author(s):  
S.K. Mukherjee ◽  
S. Kumar ◽  
P.K. Srivastava ◽  
Arbind Kumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining
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