Modelling and Analysis of Pulse Electrochemical Machining (PECM)

1994 ◽  
Vol 116 (3) ◽  
pp. 316-323 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
B. Wei
Keyword(s):  
Anodic Dissolution ◽  
Experimental Studies ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Tool Design ◽  
Machining Parameters ◽  
Electrolyte Flow ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap ◽  
Continuous Current

A small interelectrode gap in Electrochemical Machining (ECM) results in improved dimensional accuracy control and simplified tool design. However, using a small gap with conventional ECM equipment adversely affects the electrolyte flow or mass transport conditions in the gap, leading to process instability. The most remarkable breakthrough in this regard is the development of ECM using pulsed current. Pulse Electrochemical Machining (PECM) involves the application of a voltage pulse at high current density in the anodic dissolution process. PECM allows for more precise monitoring and control of machining parameters than ECM using continuous current. Small interelectrode gap, low electrolyte flow rate, gap state recovery during the pulse-off times and improved anodic dissolution efficiency features encountered in PECM lead to improved workpiece precision and surface finish when compared with ECM using continuous current. This paper presents mathematical models for the PECM process which take into consideration the nonsteady physical phenomena in the gap between the electrodes, including the conjugate fields of electrolyte flow velocities, pressure, temperature, gas concentrations, current densities and anodic material removal rates. The principles underlying higher dimensional accuracy and simpler tool design attainable with optimum pulse parameters are also discussed. Experimental studies indicate the validity of the proposed PECM models.

Pressure Generated During Pulse Electrochemical Machining

2001 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar
Keyword(s):  
High Speed ◽  
Turbine Blades ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap ◽  
Complex Shapes ◽  
High Speed Data Acquisition ◽  
High Speed Data

Abstract Pulse electrochemical machining (PECM) provides an economical and effective method for machining high strength, heat-resistant materials into complex shapes such as turbine blades of titanium alloys. The dimensional accuracy of PECM can be improved if a small interelectrode gap is maintained. This paper presents an interelectrode gap model for estimating pulse pressure generated after pulse current switched on, and the subsequent dynamic loading on the electrodes during PECM. A specially built PECM cell and a high-speed data acquisition system are used to measurement of wave pressure for verification of estimated values.

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.

Modelling and Monitoring Interelectrode Gap in Pulse Electrochemical Machining

CIRP Annals ◽  
1995 ◽  
Vol 44 (1) ◽  
pp. 177-180 ◽  
Author(s):  
K.P. Rajurkar ◽  
B. Wei ◽  
J. Kozak ◽  
J.A. McGeough
Keyword(s):  
Electrochemical Machining ◽  
Pulse Electrochemical Machining ◽  
Interelectrode Gap

Analytical and Experimental Study of Electrochemical Micromilling

2015 ◽  
Vol 5 (2) ◽  
pp. 1-16 ◽  
Author(s):  
Abishek B. Kamaraj ◽  
Murali M. Sundaram
Keyword(s):  
Mathematical Model ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Electrochemical Micromachining ◽  
Manufacturing Method ◽  
Conductive Materials ◽  
Interelectrode Gap ◽  
Wide Range ◽  
Machining System

Electrochemical micromachining (ECMM) is a non-conventional manufacturing method suitable for the production of microsized components on a wide range of conductive materials. ECMM improves dimensional accuracy and simplifies tool design for machining hard, high strength, heat resistant, and conductive materials into complex shapes. Extremely small interelectrode gaps of the order of few microns are required in ECMM for better dimensional accuracy. However, excessively small interelectrode gaps may lead to complications, such as short-circuiting, which disrupt the stability of ECMM process. This necessitates the need for better understanding of the interelectrode gap dynamics. This paper presents a mathematical model for the analysis of interelectrode gap under non-steady state conditions in micromilling of steel using the ECMM process. Experimental verification of the mathematical model was conducted using an in-house built micro electrochemical machining system. The model is capable of predicting the machining results to within 1- 5 µm error (10- 50%).

Technical Study of Laminated Template Electroforming in Fabrication of Metal Parts

2014 ◽  
Vol 621 ◽  
pp. 121-126
Author(s):  
Hui Fan ◽  
Yang Pei Zhao
Keyword(s):  
Experimental Studies ◽  
Small Diameter ◽  
Dimensional Accuracy ◽  
Spray Distance ◽  
Metal Parts ◽  
Precise Locality ◽  
Filling Method ◽  
Specific Shape ◽  
Technical Study ◽  
Equipment Configuration

Laminated templates electroforming (LTE) is one kind of metal-parts directly forming technologies which are based on discrete/accumulation theory. This paper introduces the forming principle, equipment configuration and experimental studies. By using templates as auxiliary tool and jet electroforming as filling method, the current density of electroforming was significantly improved and a group of copper parts in specific shape were fabricated. Experimental results show that on-load voltage, nozzle diameter, spray distance, spray flow velocity have direct influence on processing speed and locality. A small diameter of nozzle and short spray distance helps to achieve a precise locality and good dimensional accuracy, after process parameters have been optimized.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

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