Low-Cost Tool Design for Pulse-Reverse Electrochemical Machining of Aerospace Alloys via Multiphysics Simulation

2021 ◽  
Vol MA2021-02 (25) ◽  
pp. 803-803
Author(s):  
Andrew Moran ◽  
Brian Skinn ◽  
Stephen Snyder ◽  
Timothy Hall ◽  
E. Jennings Taylor
Keyword(s):  
Low Cost ◽  
Electrochemical Machining ◽  
Tool Design ◽  
Multiphysics Simulation ◽  
Aerospace Alloys ◽  
Pulse Reverse

Accelerated Electrochemical Machining Tool Design via Multiphysics Modeling

2017 ◽  
Vol 77 (11) ◽  
pp. 963-979
Author(s):  
Brian Skinn ◽  
Timothy D Hall ◽  
Stephen Snyder ◽  
K. P. Rajurkar ◽  
E. J. Taylor
Keyword(s):  
Electrochemical Machining ◽  
Tool Design ◽  
Multiphysics Modeling

scholarly journals Characterization of an Electrochemical Machining Process for Precise Internal Geometries by Multiphysics Simulation

Procedia CIRP ◽  
2017 ◽  
Vol 58 ◽  
pp. 175-180 ◽  
Author(s):  
Matthias Hackert-Oschätzchen ◽  
Raphael Paul ◽  
Michael Kowalick ◽  
Danny Kuhn ◽  
Gunnar Meichsner ◽  
...  
Keyword(s):  
Electrochemical Machining ◽  
Machining Process ◽  
Multiphysics Simulation

scholarly journals (ECS 234th) Multiphysics Modeling Prediction of Electrochemically Machined Through-Hole Geometries

2018 ◽  
Author(s):  
Brian Skinn ◽  
Tim Hall ◽  
Stephen Snyder ◽  
KP Rajurkar ◽  
Jennings E. Taylor
Keyword(s):  
Electrochemical Machining ◽  
High Strength ◽  
Mirror Image ◽  
Simulation Software ◽  
Manufacturing Technology ◽  
Tungsten Alloy ◽  
Machining Processes ◽  
Predictive Tool ◽  
Multiphysics Simulation ◽  
Through Hole

Electrochemical machining (ECM) is a manufacturing technology that allows metal to be precisely removed by electrochemical oxidation and dissolution into an electrolyte solution. ECM is suited for machining parts fabricated from “difficult to cut” materials and/or parts with complicated and intricate geometries. In ECM, the workpiece is the anode and the tool is the cathode in an electrochemical cell; by relative movement of the shaped tool into the workpiece, the mirror image of the tool is “copied” or machined into the workpiece. Compared to mechanical or thermal machining processes where metal is removed by cutting or electric discharge/laser machining, respectively, ECM does not suffer from tool wear or result in a thermally damaged surface layer on the workpiece. Consequently, ECM has strong utility as a manufacturing technology for fabrication of a wide variety of metallic parts and components, and includes machining, deburring, boring, radiusing and polishing processes. ECM provides particular value in that application is straightforward to high strength/tough and/or work-hardening materials such as high strength steel, chrome-copper alloy (C18200), nickel alloy (IN718), cobalt-chrome alloy (Stellite 25) and tantalum-tungsten alloy (Ta10W), since the material removal process involves no mechanical interaction between the tool and the part. A variety of production applications are envisioned as well suited for ECM techniques.One notable difficulty with ECM, common to a variety of manufacturing operations, is an inability to predict a priori the tool and process parameters required in order to satisfy the final specifications of the fabricated part. In this talk, Faraday will present results from ongoing development work of a physics-based design platform to predict optimal ECM tool shape using commercially available multiphysics simulation software. This predictive capability is anticipated to dramatically shorten the process/tooling development cycle, eliminating much or all of the iterative prototyping necessary in the absence of a predictive tool. The main focus of this talk will be a comparison of through-holes fabricated by CM in flat plate and/or tube geometries to those predicted by multiphysics simulation. The various physics included in the models to enable accurate simulations will be discussed, along with any (semi-)empirical simplifying assumptions made to accelerate execution of the simulations. The overarching objective of the current and future work, to demonstrate accurate modeling of ECM through-hole features of progressively increasing experimental complexity, will also be presented.

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

The tool design and experiments on electrochemical machining of a blisk using multiple tube electrodes

2015 ◽  
Vol 79 (1-4) ◽  
pp. 531-539 ◽  
Author(s):  
Zhengyang Xu ◽  
Jia Liu ◽  
Qing Xu ◽  
Ting Gong ◽  
Dong Zhu ◽  
...  
Keyword(s):  
Electrochemical Machining ◽  
Tool Design

Figuring of Aspherical Metal Mirror Substrate for Neutron Focusing by Numerically Controlled Electrochemical Machining

2012 ◽  
Vol 523-524 ◽  
pp. 29-33 ◽  
Author(s):  
Takaaki Tabata ◽  
Mikinori Nagano ◽  
Dai Yamazaki ◽  
Ryuji Maruyama ◽  
Kazuhiko Soyama ◽  
...  
Keyword(s):  
Neutron Beam ◽  
Low Cost ◽  
Electrochemical Machining ◽  
Cost Effective ◽  
Chromatic Aberration ◽  
Fabrication Process ◽  
Proton Accelerator ◽  
X Rays ◽  
Accelerator Facility ◽  
Aspherical Mirror

Neutron beam generated by high intensity proton accelerator facility is powerful tool to investigate characteristics of soft and hard materials. However, neutron beam is not major tool for material science since intensity of neutron beam is very weak compared to that of X-rays. Neutron focusing device is required to increase in intensity of neutron beam. Aspherical supermirror is effective for neutron focusing with wide wavelength range without chromatic aberration. In this research, we proposed a fabrication process for large and cost-effective aspherical mirror substrate made of aluminum alloy because metal can be figured coarsely at low cost by using conventional machining. The mirror fabrication process proposed by us consists of grinding for coarse figuring, numerically controlled electrochemical machining (NC-ECM) to correct objective shape with form accuracy of sub-micrometer level and low-pressure polishing to decrease in surface roughness to sub-nanometer level. In the case of figure correction of the mirror substrate by NC-ECM, deterministic correction is realized because NC-ECM is a non-contact electrochemical removal process for metal materials, without workpiece deformation. In this paper, we report fundamental machining characteristics of ECM, which uses electrode with a diameter of 10 mm and NaNO3 electrolyte.

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.

Sign in / Sign up

Export Citation Format

Share Document