scholarly journals Impact of Different Electrolytes on the Machining Rate in ECM Process

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
K. G. Saravanan ◽  
R. Prabu ◽  
A. R. Venkataramanan ◽  
Eden Tekle Beyessa
Keyword(s):  
Metal Removal ◽  
Electrochemical Machining ◽  
Tool Material ◽  
Electrochemical Process ◽  
Machining Process ◽  
Complexing Agents ◽  
Workpiece Material ◽  
Electrolysis Process ◽  
Machining Rate ◽  
The Impact

Electrochemical machining is a nonconventional machining process in which the metal removal is achieved by the electricity and chemical solution known as an electrolyte. It is the reverse electrolysis process where the application of electricity facilitates the current travel in between anode and cathode. The mechanism of the ion movement is similar to the electrolysis process. Electrochemical machining (ECM) is a type of advanced machining process which employs electricity to perform the machining process on the workpiece. It is also known as a reverse electroplating process where metal removal is achieved instead of metal deposition on the metal surface. There are various parameters that affect the metal removal process in the ECM process, such as electrolyte, power supply, workpiece material, and tool material. The electrolyte is one of the key factors impacting the machining rate, surface finish, and reliability of the produced parts. In this project, a brief study is carried out regarding the electrochemical process and the electrolytes where the properties, functions, merits, and demerits are evaluated. The impact of the various electrolytes and their suitability for machining of various metals is also discussed. The findings of the effect produced by using the mixture of the electrolyte in the electrochemical machining process are discussed in this project. The effects of the complexing agents on the electrolyte and the electrochemical process as a whole are also reviewed.

Study of Electrochemical Jet Machining Process

1996 ◽  
Vol 118 (4) ◽  
pp. 490-498 ◽  
Author(s):  
J. Kozak ◽  
K. P. Rajurkar ◽  
R. Balkrishna
Keyword(s):  
Turbine Blades ◽  
Electrochemical Machining ◽  
Small Diameter ◽  
Machining Process ◽  
Workpiece Material ◽  
Precise Control ◽  
Machining Rate ◽  
Jet Electrochemical Machining ◽  
The Relationship ◽  
Electrolyte Jet

Jet Electrochemical Machining (ECJM) employs a jet of electrolyte for anodic dissolution of workpiece material. ECJM is extensively used for drilling small cooling holes in aircraft turbine blades and for producing maskless patterns for microelectronics parts. ECJM process drills small diameter holes and complex shape holes without the use of a profile electrode. One of the most significant problems facing ECJM user industries is the precise control of the process. A theoretical analysis of the process and a corresponding model are required for the development of an appropriate control system. This paper presents a mathematical model for determining the relationship between the machining rate and working conditions (electrolyte jet flow velocity, jet length, electrolyte properties, and voltage) of ECJM. This model describes a distribution of electric field and the effect of change of conductivity of electrolyte (caused by heating) on the process performance. A maximum dissolution rate is determined from the allowable increase of electrolyte temperature. Experimental verification of theoretical results is also presented.

scholarly journals 2D Electrochemical Airfoil Machining Process Model

1995 ◽  
Author(s):  
H. A. Nied ◽  
M. S. Lamphere
Keyword(s):  
Process Model ◽  
Complex Geometry ◽  
Shape Change ◽  
Electrochemical Machining ◽  
Aircraft Engine ◽  
Machining Process ◽  
Field Equations ◽  
Workpiece Material ◽  
Faraday’S Law ◽  
Numerical Predictions

A 2D Electro-Chemical Machining (ECM) process model was developed to aid with tooling design and process optimization by simulation of the ECM process. The boundary element method (BEM) was used to numerically solve the field equations of the process model. The electrochemical anodic reaction was furnished by Faraday’s Law, which provided the relationship for the rate of dissolution at the surface of the workpiece as a function of charge transfer. Accordingly, the workpiece shape change and mass of metal removed by the machining process can be determined as a function of time. The process model includes a library of workpiece material and electrolyte combinations for predicting the electrochemical machining behavior, e.g., titanium alloy 6Al-4V and NaCl electrolytes. These metal/electrolyte combinations are of special interest in the aircraft engine industry for manufacturing heat-resistant, rotary components with complex geometry such as airfoil blades. The major features of the numerical computer program are briefly described with a selected example of machining a typical fan blade. Preliminary comparison of the numerical predictions with the nominal airfoil geometry showed good agreement and is discussed below.

scholarly journals Removal of nickel through sulfide precipitation and characterization of electroplating wastewater sludge

2020 ◽  
Vol 55 (4) ◽  
pp. 345-357
Author(s):  
Sarah Jerroumi ◽  
Mohammed Amarine ◽  
Hassan Nour ◽  
Brahim Lekhlif ◽  
Jamal Eddine Jamal
Keyword(s):  
Removal Efficiency ◽  
Metal Removal ◽  
Operating Conditions ◽  
Wastewater Sludge ◽  
Complexing Agents ◽  
Optimal Dosage ◽  
Electroplating Wastewater ◽  
Sulfide Precipitation ◽  
The Impact

Abstract This work consists of the removal of nickel by sulfide precipitation from industrial electroplating wastewater and characterization of the produced sludge. Tests are carried out in a perfectly stirred batch reactor on electroplating industrial solution and synthetic solution prepared in the laboratory. The aim is to evaluate the impact of complexing agents formed during precipitation of metal ions in the industrial effluent. The concentration of nickel in both solutions is 100 mg/L. The operating conditions for the sulfide precipitation process are optimized: pH, molar ratio [S=]/[Ni2+] and dosage of S= ions. For an initial pH of 5 and an equimolar ratio of [S=]/[Ni2+]:1/1, the results show that the removal efficiency of Ni2+ ions is approaching 91 and 94% for industrial and synthetic solutions, respectively. Otherwise, for the same pH value in supersaturation conditions ([S=]/[Ni2+]:1.5/1), the removal efficiency is approaching 62 and 92% for industrial and synthetic solutions, respectively. For an effective metal removal, the optimal dosage of sulfide ions was evaluated. For 33 mg/L of S=, the removal efficiency of Ni2+ is approximately 90%. The resulting sludge has been characterized by X-ray diffractometry, scanning electron microscopy, infrared spectroscopy and thermal analysis. It consists essentially of millerite and nickel oxide.

The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3583-3586 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Three Dimension ◽  
Cathode Design ◽  
Aero Engine ◽  
Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

Study on the Orthogonal Cutting Process of Al7050T7451 with Uncoated and Coated Tools

2008 ◽  
Vol 392-394 ◽  
pp. 990-995 ◽  
Author(s):  
Hui Yue Dong ◽  
Pu Jin Huang ◽  
Y.B. Bi
Keyword(s):  
Finite Element ◽  
High Speed ◽  
High Strain ◽  
Bulk Material ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Machining Process ◽  
Workpiece Material ◽  
Coated Tool ◽  
The Impact

Tool wear during high speed machining process plays an important role in machining cost and efficiency. The purpose of this study is to examine the impact of tribological properties of coatings on cutting performance. Finite element methods (FEM) were used to model the effect of coated and uncoated cutting tools (K10) on the machinability of the aluminum alloy 7050T7451. Uncoated, Single coated, such as TiC, TiN and Al2O3 and multi-coated tool were studied. All finite element models were assumed to be plane strain. To achieve constitutive model of Al7050T7451 under conditions of machining that high strain rate, high strain and high temperature occur, high speed impact experiment and material drawing experiment were done. Comparison of FEM results shows that the highest temperatures in tools, the temperature change rates of different tools from surface to its bulk material, and the temperatures in chips are changed greatly. It also shows that the cutting temperature of coated tool is lower than uncoated tools, but cutting forces change very little. All these results show that coatings can be used to reduce adhesion between a tool and a workpiece material. The wear resistance of coated tool can be improved effectively and tool life is increased correspondingly.

Effect of Materials on the Mechanism of Electric Discharge Machining (E.D.M.)

1983 ◽  
Vol 105 (2) ◽  
pp. 132-138 ◽  
Author(s):  
A. Erden
Keyword(s):  
Electric Discharge ◽  
Particle Concentration ◽  
Electrode Materials ◽  
Tool Material ◽  
Mathematical Expression ◽  
Machining Process ◽  
Time Lags ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Workpiece Material

Electric Discharge Machining process is investigated both theoretically and experimentally to determine the effects of electrode materials on the machining performance. For this purpose a single and isolated spark is physically and mathematically modelled, and its three phases; viz., Breakdown, Discharge and Erosion are investigated. Resolidified electrode materials as suspended particles in the dielectric liquid are found to be the most significant factor in the breakdown phase. Mathematical expressions relating the time lags to particle concentration are given which can be used to determine the effects of particle concentration on the machining performance. Discharge properties are shown to be dependent on the discharge medium which includes vapours of the electrode materials. The polarity effect has been studied both theoretically and experimentally. Some qualitative explanation is given for the erosion phase. Importance of electrical forces is discussed and a simple mathematical expression is given for the erosion phase. It is concluded that optimum machining conditions can only be obtained by proper selection of the tool material, workpiece material and discharge medium since they affect the initiation and development of the discharge and erosion of electrode materials.

Tool Diffusion Wear Mechanism in High Efficiency Machining Ti6Al4V

2013 ◽  
Vol 579-580 ◽  
pp. 3-7
Author(s):  
Yi Hang Fan ◽  
Zhao Peng Hao ◽  
Min Li Zheng ◽  
Feng Lian Sun ◽  
Suo Liang Niu
Keyword(s):  
High Efficiency ◽  
Diffusion Mechanism ◽  
Cutting Temperature ◽  
Tool Material ◽  
Machining Process ◽  
Rake Face ◽  
Workpiece Material ◽  
Machined Surface ◽  
Diffusion Wear ◽  
Flank Face

Ti6Al4V has great affinity with tool material in machining process, which easily leads to tool diffusion wear. Turning experiments were carried out to study cutting temperature and pressure at tool-chip/workpiece. Based on the analysis, a scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectrometer (EDS) was used to analyze tool wear morphology. The affinity of tool and workpiece material using the Ti-W, Ti-Co diagram was also studied to elaborate the diffusion mechanism in this present study. The results shows that the cutting temperature is very high and the temperature increases with the increase of cutting speeds in machining Ti6Al4V. At the contact area, the highest temperature is located in tool rake face near to tool tip. The resilience of workpiece results in serious attrition between tool flank face and the machined surface. The highest pressure is located in tool flank face near to tool tip and the pressure in tool-workpiece interface is much higher than that in tool-chip interface. Under the high cutting temperature and high pressure at tool-chip/workpiece interface, diffusion occurred both at tool rake an flank face in machining Ti6Al4V. Because of the higher temperature at tool rake face diffusion at tool rake face ia more sever than that at tool flank face.

scholarly journals An Evaluation of Ploughing Models for Orthogonal Machining

1999 ◽  
Vol 121 (4) ◽  
pp. 550-558 ◽  
Author(s):  
D. J. Waldorf ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Cutting Tool ◽  
Metal Removal ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Machining Process ◽  
Separation Point ◽  
Workpiece Material ◽  
Orthogonal Machining ◽  
Edge Component ◽  
Material Separation

An analytical comparison is made between two basic models of the flow of workpiece material around the edge of an orthogonal cutting tool during steady-state metal removal. Each has been the basis for assumptions in previous studies which attempt to model the machining process, but no direct comparison had been made to determine which, if either, is an appropriate model. One model assumes that a separation point exists on the rounded cutting edge while the other includes a stable build-up adhered to the edge and assumes a separation point at the outer extreme of the build-up. Theories of elastic-plastic deformation are employed to develop force predictions based on each model, and experiments are performed on 6061-T6 aluminum alloy to evaluate modeling success. The experiments utilize unusually large cutting edge radii to isolate the edge component of the total cutting forces. Results suggest that a material separation point on the tool itself does not exist and that the model that includes a stable build-up works better to describe the experimental observations.

THE PHENOMENON OF SURFACE MODIFICATION BY ELECTRO-DISCHARGE COATING PROCESS: A REVIEW

2018 ◽  
Vol 25 (01) ◽  
pp. 1830003 ◽  
Author(s):  
SUJOY CHAKRABORTY ◽  
SIDDHARTHA KAR ◽  
VIDYUT DEY ◽  
SUBRATA KUMAR GHOSH
Keyword(s):  
Surface Modification ◽  
Substrate Surface ◽  
Tool Material ◽  
Machining Process ◽  
Machining Processes ◽  
Workpiece Material ◽  
Modification Technique ◽  
Inherent Nature ◽  
Conventional Machining ◽  
Edm Process

Electro-discharge machining (EDM) process is one of the most successful non-conventional machining processes for the last three to four decades in machining very hard materials which are tough to machine by conventional machining process. In the EDM process, besides the erosion of workpiece material, the inherent nature of the process leads to some tool material removal also. This nature of EDM process has been exploited by the researchers which led to the invention of Electro-discharge coating (EDC). EDC is a surface modification technique where tool material gets deposited on the substrate surface due to the sparking effect. It works on reverse polarity to that of EDM. A literature review based on the phenomenon of surface improvement by EDC process and also the future drifts of its application are shown in this paper.

Simulation Analysis of RuT450 Drilling Force Based on LS-DYNA Gun Drilling

2018 ◽  
Vol 764 ◽  
pp. 271-278 ◽  
Author(s):  
H. Guo ◽  
W. Yang ◽  
L. Liu ◽  
X.K. Yang ◽  
Y.G. Wang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Equivalent Stress ◽  
Cutting Speed ◽  
Machining Process ◽  
Cutting Fluid ◽  
Drilling Process ◽  
Drilling Force ◽  
Workpiece Material ◽  
The Impact

Cutting force is one of the most important parameters in the machining process, it significantly influenced machining precision of the workpiece, power consumed in the machining process, wear of the cutting tools and so on. There are many factors that affect the cutting force, such as the performance of the workpiece material, cutting speed, usage of the cutting fluid, etc. Single factor variable method was used in this paper, RuT450 was used as workpiece, welded cemented carbide gun drill was used as cutting force and LS-DYNA was used as simulation platform to established the cutting simulation model to analyzed the impact of the cutting speed and feed rate to the drilling force. Simulation results show that, at the low speed drilling stage, drilling force increases with the increase of the feed rate and decreases with the increase of the rotation feed, from the stress cloud it could be seen that the equivalent stress near the drill tip reached the maximum in the drilling process.

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