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.

scholarly journals Flushing Enhancement with Vibration and Pulsed Current in Electrochemical Machining

2017 ◽  
Vol 2 (4) ◽  
pp. 67-85 ◽  
Author(s):  
Zhujian Feng ◽  
Jesus Manuel Orona-Hinojos ◽  
Pedro Perez Villanueva ◽  
Paul Lomeli ◽  
Wayne NP Hung
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Three Dimensional ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Steel Plates ◽  
Electrode Gap ◽  
Taper Angle ◽  
Low Frequency Vibration

This research aims to understand flushing of by-products in electrochemical machining (ECM) by modeling and experimentally verifying mechanism of particle transport in inter-electrode gap under low frequency vibration. A series of hole were drilled on steel plates to evaluate the effect of vibration on material removal rate and hole quality. Infinite focus optical technique was used to capture and analyze the three-dimensional images of ECM'ed features. Experimental results showed that maximum machining depth and minimum taper angle can be achieved when vibrating the workpiece at 40 Hz and 10 µm amplitude. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at this vibration frequency and amplitude. Machining depth and material removal rate has a positive correlation with the average flushing speed. Sharper ECM’ed profile is obtained since the taper angle is favorably reduced at high average flushing speed.

Optimization of Process Parameters for Electro-Chemical Machining of EN19

2019 ◽  
pp. 127-142 ◽  
Author(s):  
Divya Zindani ◽  
Nadeem Faisal ◽  
Kaushik Kumar
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Input Parameter ◽  
Electrochemical Machining ◽  
Pso Algorithm ◽  
Machining Process ◽  
Matrix Composites ◽  
Machining Performance ◽  
Electrode Gap ◽  
Optimization Of Process Parameters

Electrochemical machining (ECM) is a non-conventional machining process that is used for machining of hard-to-machine materials. The ECM process is widely used for the machining of metal matrix composites. However, it is very essential to select optimum values of input process parameters to maximize the machining performance. However, the optimization of the output process parameters and hence the machining performance is a difficult task. In this chapter an attempt has been made to carry out single and multiple optimization of the material removal rate (MRR) and the surface roughness (SR) for the ECM process of EN19 using the particle swarm optimization (PSO) technique. The input parameter considered for the optimization are electrolyte concentration (%), voltage (V), feed rate (mm/min), and inter-electrode gap (mm). The optimum value of MRR and SR as found using the PSO algorithm are 0.1847 cm3/min and 25.0612, respectively.

Study of Pulse Electrochemical Machining Performance of Deep-Small Hole on Nickel-Based Alloy

2011 ◽  
Vol 204-210 ◽  
pp. 1830-1834
Author(s):  
Zhao Long Li ◽  
Shi Chun Di
Keyword(s):  
Base Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Performance ◽  
Math Model ◽  
Technical Parameters ◽  
Pulse Electrochemical Machining ◽  
Small Holes

The method of machining deep hole on Ni-base alloy which can tolerant high temperature by pulse electrochemical machining has been proposed in this paper. Five technical parameters are discussed on the effect of mass removal rate of machining process. Establish a dynamic math model, and analyze the effect of process parameters on the mass material removal rate of deep small holes. Machining accuracy of deep small holes was analyzed.

Removal of Defective Layer after Electrical Discharge Machining

2019 ◽  
Vol 973 ◽  
pp. 157-160
Author(s):  
Stanislav A. Mozgov ◽  
Yuriy A. Morgunov ◽  
Boris P. Saushkin
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Work Piece ◽  
Machining Parameters ◽  
Electrode Gap ◽  
Machining Time ◽  
Defective Layer

This study investigates the possibility of electrochemical removal of the defective layer formed on the surface of the product after its electrical discharge machining. A set of experiments was conducted in different electrolytes based on aqueous and aqueous-organic solvents. The experiments were to trace the influence of such settings of electrochemical machining as current density, electrolyte pumping speed, electrolyte temperature, and an electrode gap upon both the dynamics of metal removal and surface quality. Morphology of the obtained surface was examined by an Olympus BX-51Microscope. The dynamics of removing material (stock) from the work piece was inspected. Appropriate adjustments were made to the machining parameters during the machining of 65G steels, and a preferred composition was selected for the working medium. A sufficient design for production tools was proposed. Pitting corrosion was discovered on the surface of the samples in all studied modes of electrolysis. It was observed that switching from aqueous electrolyte to aqueous-organic electrolyte gave lower material removal rate and longer machining time accordingly. At the same time, a reduction in surface roughness was visualized, together with smaller pits and lower density of their distribution. The obtained results may be applied in operation design for electrochemical machining of steels with relatively high carbon contents.

Investigations on Machining of Monel 400 Alloys Using Electrochemical Machining with Sodium Nitrate as Electrolyte

2014 ◽  
Vol 592-594 ◽  
pp. 467-472 ◽  
Author(s):  
M. Kalaimathi ◽  
G. Venkatachalam ◽  
Neil Pradeep Makhijani ◽  
Ankit Agrawal ◽  
M. Sivakumar
Keyword(s):  
Process Parameters ◽  
Sodium Nitrate ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Research Field ◽  
Electrode Gap ◽  
Conventional Machine ◽  
Monel 400 ◽  
Physical And Chemical ◽  
The Impact

Monel 400 is a cuprous nickel alloy which is very well-known for its resistivity towards physical and chemical strength. It is probably one of the hardest and most non-corrosive materials known in industrial as well as research field. These properties have enhanced its applications in various fields such as aerospace industries, marine industries, automotive industries etc. Monel 400 alloys are too hard to machine using conventional machine tools and methods as it work hardens rapidly on its surface. Authors concluded that electrochemical machining is the choice of machining of these materials. The present work is carried out to analyze the impact of ECM process parameters such as applied voltage (V), inter-electrode gap (IEG) and electrolyte concentration (EC) on material removal rate (MRR) and surface roughness (Ra). An aqueous sodium nitrate (NaNO3) is used as basic electrolyte in the electrochemical machining of Monel 400 alloys. Response surface methodology (RSM) based central composite design (CCD) is used as experimental strategy. Effects of process parameters as well as their interactions are analysed and the process parameters are optimized.

Process Simulation of Electrochemical Machining of Convexity Structure on Revolving Workpiece

2015 ◽  
Author(s):  
Zengwei Zhu ◽  
Dengyong Wang ◽  
Jun Bao ◽  
Di Zhu
Keyword(s):  
Mathematical Model ◽  
Process Simulation ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Relative Rotation ◽  
Electrode Gap ◽  
Simulation Results

A special electrochemical machining (ECM) process using a revolving cathode tool with hollow windows is presented. Unlike conventional sinking ECM, this presented ECM process fabricates the convexity structures on a revolving part by the relative rotation of anode workpiece and cathode tool. In this paper, a mathematical model is established to describe the evolution of the machining process, the finite element simulations of the new forming fashion are focused for the workpiece’s revolving surface and the convexity’s side profile. The simulation results show that both the cathode feed rate and the applied voltage have significant influence on the equilibrium inter-electrode gap and the material removal rate. The side profile of the convexity is related to radius of the cathode tool. It is expected that the equilibrium gap and steady removal rate could be achieved by optimizing the cathode feed rate and the voltage, the required side profile taper of the convexity could be obtained by selecting the proper tool radius.

Study of Micro-EDM of Tungsten Carbide with Workpiece Vibration

2011 ◽  
Vol 264-265 ◽  
pp. 1056-1061 ◽  
Author(s):  
Muhammad Pervej Jahan ◽  
T. Saleh ◽  
Mustafizur Rahman ◽  
Yoke San Wong
Keyword(s):  
Tungsten Carbide ◽  
Surface Quality ◽  
Removal Rate ◽  
Low Frequency ◽  
Electrode Wear ◽  
Micro Edm ◽  
Machining Performance ◽  
Machining Time ◽  
Workpiece Vibration ◽  
Micro Holes

Present study introduces low-frequency workpiece vibration during micro-EDM drilling of difficult-to-cut tungsten carbide with an objective to overcome the difficulty in flushing of debris and machining instability in deep-hole machining. The effects of vibration frequency, amplitude and electrical parameters on the machining performance, as well as surface quality and accuracy of the micro-holes have been investigated. It is found that the overall machining performance improves significantly with significant reduction of machining time, increase in material removal rate (MRR), and decrease in electrode wear ratio (EWR). The surface quality improves and the overcut and taper angle of the micro-holes reduces after applying the workpiece vibration in micro-EDM. The frequency and amplitude of 750 Hz and 1.5 μm were found to provide optimum performance.

scholarly journals Computer Simulation of Low Frequency Vibration in Electrochemical Machining

2021 ◽  
Vol 6 (1) ◽  
pp. 1-21
Author(s):  
Wayne NP Hung ◽  
Zhujian Feng ◽  
Paul Lomeli
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Ansys Fluent ◽  
Taper Angle ◽  
Low Frequency Vibration ◽  
Particle Speed ◽  
40 Hz

This research studies how particles transport between low frequency vibrating electrodes during electrochemical machining (ECM). The ANSYS Fluent software was used to study the particle speed while the Star CCM+ software was utilized to study particle interactions during vibration-assisted ECM process. A series of simulations were conducted to calculate the particle average flushing speed. Collided particles either gained momentum or deflected their trajectories to accelerate in the flow of electrolyte. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at 40 Hz vibration frequency and 10 µm vibration amplitude. Such higher flushing speed of particles improved machining depth (material removal rate) and produced a sharper machined profile. Experiment results confirmed that the maximum machining depth and minimum taper angle were obtained when vibrating the anodic workpiece at 40 Hz and 10 µm amplitude. Machining depth and ECM material removal rate had a positive correlation with the average flushing speed. A sharper ECM’ed profile was achieved since the taper angle was favorably reduced at high average flushing speed.

scholarly journals Optimization of Process Parameters During Electrochemical Machining

2019 ◽  
Vol 8 (12) ◽  
pp. 2683-2687
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Research Work ◽  
Electrochemical Machining ◽  
Machining Processes ◽  
Electrode Gap ◽  
Optimization Of Process Parameters ◽  
Finishing Process ◽  
Nimonic 80A ◽  
The Right

Electrochemical machining is one of the most efficient machining processes due to its ability to produce completely stress-free machined components without any need of further finishing process. However, the right understanding of the effects of key factors during machining of various materials is very important to carry out the machining. It is one of the most efficient way of cutting present in modern era. This present paper deals with the electrochemical machining of Nimonic 80A. Design of the experiments are done by using response surface methodology to study the material removal rate and surface roughness. Process parameters such as voltage, tool feed rate, inter-electrode gap and electrolyte concentration has been optimized by using the ANOVA. The regression models are developed to be used as predictive tools. The confirmation test was conducted to validate the results achieved by GRA approach. This research work helps the industrialist for selecting parameters to attain desired outputs.

scholarly journals The effects of the process parameters in electrochemical machining on the surface quality

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Nguyen Thi Bich Nhung ◽  
Dao Thanh Liem ◽  
Truong Quoc Thanh
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Electrode Gap

Based on the number of previous studies, this study aims to investigate the effects of process parameters of an Electrochemical Machining process, which are electrolyte concentration, the voltage applied to the machine, feed rate of the electrode, and Inter-Electrode Gap between tool and workpiece. Aluminum samples of 25 mm diameter x 25 mm height and 30mm diameter x 25mm height of the tool is made up of copper with a circular cross-section with 2 mm internal hole. The design of the system is based on the Taguchi method. Here, the signal-to-noise (S/N) model, the analysis of variance (ANOVA) and regression analyses are applied to determine optimal levels and to investigate the effects of these parameters on surface quality. Finally, the experiments that use the optimal levels of machining parameters are conducted to verify the effects of the process parameters on the surface quality of the products. The results pointed out a set of optimal parameters of the ECM process. The Inter-Electrode Gap between the tool and workpiece has extremely effected on these Material Removal rates and surface roughness. The Material Removal Rate increases with diseases in Inter-Electrode Gap, and Ra diseases with diseases in Inter-Electrode Gap. The experimental results show that maximum Material Removal Rate has obtained with electrolyte concentration at 100 g/l, feed rate at 0.0375 mm/min, the voltage at 15V, and Inter-Electrode Gap at 0.5mm. The minimum Ra has obtained with electrolyte concentration at 80 g/l, feed rate at 0.0468 mm/min, the voltage at 10V, and Inter-Electrode Gap at 0.5mm. This result has led to need studies on these parameters in Electrochemical Machining, which are improving productivities and surface roughness of the products.   

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