Simulation and Experimental Study on Improving Electrochemical Machining Stability of High Convex Structure on Casing Surface by Using Backwater Pressure

2021 ◽  
Author(s):  
Zhenghui Ge ◽  
Wangwang Chen ◽  
Yongwei Zhu
Keyword(s):  
Flow Field ◽  
Electrochemical Machining ◽  
Back Pressure ◽  
Convex Structure ◽  
Flow Field Characteristics ◽  
Simulation And Experiment ◽  
Different Shapes ◽  
Simulation Results ◽  
Structure Height ◽  
Engine Components

Abstract Casing parts are regarded as one of the key components in aero-engine components. Most casing parts are attached with different shapes of convex structures, and their heights range from hundreds of microns to tens of millimeters. The use of profiling blocky electrodes for electrochemical machining of casing parts is a widely used method, especially in the processing of high convex structures. However, with the increase of convex structure height, the flow field of machining areas will become more complex, and short circuits may occur at any time. In this study, a method to improve the flow field characteristics of machining area by adjusting the backwater pressure is proposed, the simulation and experiment are carried out respectively. The simulation results showed that the back-pressure mehtod can significantly improve the uniformity of the flow field around the convex structure compared with the extraction outlet mode and the open outlet mode, and then the optimized back-pressure of 0.5 MPa was obtained according to simulation results. The experimental results showed that under condition of the optimized back-pressure parameters, the cathode feed-rate increased from 0.6 mm/min to 0.8 mm/min, and the convex structure with a height of 18 mm was successfully machined. This indicated that the back-pressure method is suitable and effective for the electrochemical machining of high convex structure with blocky electrode.

Simulation and Experiment Research on Liquid Channel of Diffuser Blade by Electrochemical Machining

2021 ◽  
Author(s):  
Jinkai Xu ◽  
Jin Tao ◽  
Wanfei Ren ◽  
Kun Tian ◽  
Xiaoqing Sun ◽  
...  
Keyword(s):  
Flow Field ◽  
Electrochemical Machining ◽  
Leading Edge ◽  
Feed Speed ◽  
Trailing Edge ◽  
Gap Flow ◽  
Clearance Flow ◽  
Field Uniformity ◽  
Simulation And Experiment ◽  
Channel Center

Abstract Aiming to solve the problems of the low electrolyte flow rate at leading edge and trailing edge and poor uniformity of the end clearance flow field during the electrochemical machining (ECM) of diffuser blades, a gap flow field simulation model was established by designing three liquid-increasing channels at the leading edge and the trailing edge of the cathode. The simulation results indicate that the liquid-increasing hole channel (LIHC) with an outlet area S of 1.5 mm2 and a distance L from channel center to edge point of 3.2 mm achieves optimal performance. In addition, the experiment results show that the optimized cathode with liquid-increasing hole channel (LIHC) significantly improves the machining efficiency, accuracy and surface quality. Specifically, the feed speed increased from 0.25 mm/min to 0.43 mm/min, the taper decreased from 4.02° to 2.45°, the surface roughness value of blade back reduced from 1.146 µm to 0.802 µm. Moreoever, the roughness of blade basin decreased from 0.961 µm to 0.708 µm, and the roughness of hub reduced from 0.179 µm to 0.119 µm. The results prove the effectiveness of the proposed method, and can be used for ECM of other complex structures with poor flow field uniformity.

Numerical Simulation of Flow Field of Inflation Pressure for Large Complex Sulfide Mineral of Low-Tin Flotation Machine

2013 ◽  
Vol 341-342 ◽  
pp. 333-336
Author(s):  
Ming Zhen Hu ◽  
Bo Zeng Wu ◽  
Jin Quan Chen ◽  
Ji Shu Zeng
Keyword(s):  
Fluid Dynamics ◽  
Numerical Simulation ◽  
Flow Field ◽  
Sulfide Mineral ◽  
Inflation Pressure ◽  
Flotation Machine ◽  
Complex Sulfide ◽  
Flow Field Characteristics ◽  
Machine Simulation ◽  
Simulation Results

For flotation characteristics of complex sulfide mineral of low-tin in Guangxi Dachang mine, fluid dynamics software FLUENT was applied to simulate the turbulence intensity of slurry fluid in flotation machine at different inflation pressures. The effect of flow field characteristics was gotten for flotation machine. Simulation results show that the best inflation pressure was 120000 Pa.

Research on Flow Field Characteristics of Whole-Quantity-Type Safety Valve

2013 ◽  
Vol 427-429 ◽  
pp. 302-307
Author(s):  
S.H. Zou ◽  
J. Zhang ◽  
L. Gao ◽  
H. Gao ◽  
Ya Ping Wang
Keyword(s):  
Fault Diagnosis ◽  
Flow Field ◽  
Theoretical Basis ◽  
Safety Valve ◽  
Test System ◽  
Experimental Results ◽  
Type Safety ◽  
Flow Field Characteristics ◽  
Simulation Results ◽  
Structural Innovation

Emulate and analyze the flow field of whole-quantity-type safety valve using CFX. Establish the test system of whole-quantity-type safety valve. Compare the simulation results and the experimental results. Verify the accuracy of the simulation results. Provide a theoretical basis for structural innovation and fault diagnosis of whole-quantity-type safety valve.

Analysis of a Control Valve's Inner Flow Field Characteristics Based on CFD

2013 ◽  
Vol 756-759 ◽  
pp. 4652-4655
Author(s):  
Liang Wang
Keyword(s):  
Flow Field ◽  
Energy Loss ◽  
Three Dimensional ◽  
Control Valve ◽  
Flow Path ◽  
Dynamics Simulation ◽  
Flow Field Characteristics ◽  
Simulation Results

In this paper, the inner flow field characteristics of a control valve were analysed through dynamics simulation and showed by using the three-dimensional visualization. Through the analysis of simulation results, reasons were found for the energy loss, which was, then, reduced by the optimized flow path. Calculations about the optimized positions were carried out, the results of which showed an improvement of flow and a significant decrease in energy loss.

Influence of Constraint Method of Elastic Diaphragm on Numerical Simulation of Pressure-Compensating Emitter

2021 ◽  
Vol 64 (2) ◽  
pp. 425-434
Author(s):  
Xueli Chen ◽  
Zhengying Wei ◽  
Caixiang Wei ◽  
Jinpeng Ma ◽  
Zhuo Chen
Keyword(s):  
Numerical Simulation ◽  
Flow Field ◽  
Computation Time ◽  
Experimental Results ◽  
Deformation Characteristics ◽  
Structure Interaction ◽  
Contact Constraint ◽  
Flow Field Characteristics ◽  
Simulation Results ◽  
Constraint Method

HighlightsDeformation of the elastic diaphragm can affect the flow field characteristics of a pressure-compensating emitter.The contact constraint method’s simulation of the elastic diaphragm were consistent with its actual deformation.The contact constraint method can reduce the relative errors between simulated and experimental results.Abstract. Numerical simulation is an important method for revealing the working principle and optimizing the design of drip emitters. The hydraulic performance of pressure-compensating (PC) emitters is determined by the interaction between the elastic diaphragm and the flow field; therefore, correct deformation of the elastic diaphragm is one of the factors determining the accuracy of numerical simulation of PC emitters. This study investigated the effects of three constraint methods of the elastic diaphragm on the numerical simulation of PC emitters. The three methods were fully fixed constraint (FFC), upper surface fixed constraint (UFC), and contact constraint (CC). Fluid-structure interaction (FSI) simulation was used to analyze the deformation characteristics of the elastic diaphragm, the flow field characteristics, and the flow rate of the PC emitter. The simulated diaphragm deformation and flow rates were compared with the results of a visual experiment and a hydraulic performance experiment, respectively. The simulation results showed that the constraint method affected the diaphragm deformation and flow field of the PC emitter. In comparing the simulation results with the experimental results, the CC method had the highest accuracy among the three constraint methods, but an extremely long computation time was required. The FFC method had the lowest accuracy but required less computation time. The accuracy of the UFC method was lower than CC and higher than FFC, but its computation time decreased by 60.03% compared with CC. This study provides a foundation for further research on the numerical simulation and design of PC emitters. Keywords: Constraint method, Deformation characteristics, Flow field characteristics, Fluid-structure interaction, Visual experiment.

Research on Flow Field Simulation and Experiment of Numerical Control Electrochemical Machining

2010 ◽  
Vol 458 ◽  
pp. 63-68 ◽  
Author(s):  
Xiu Qing Fu ◽  
Min Kang ◽  
Q.Y. Zheng
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Numerical Model ◽  
Flow Field ◽  
Optimization Design ◽  
Electrochemical Machining ◽  
Numerical Control ◽  
Simulation And Experiment ◽  
Computational Fluid Dynamics Cfd ◽  
Cfd Method

To design the flow field of inner-spraying ball-end cathode in NC-ECM, the numerical model was bulit according to the physical model of the cathode flow channal, and the computational fluid dynamics (CFD) method was applied to slove the numerical model. The velocity and pressure distributations were obtained. The influences of the cathode internal structure and the outlet shape on the velocity of electrolyte were analyzed on the basis of the numerical simulation. The relatively good simulation results were obtained by means of the optimization design of the cathode. Based on the experiment results, the accuracy of simulation was verified, and the correction number of the design of the flow field was reduced in NC-ECM. It is indicated that the computational fluid dynamics (CFD) method can be applied to simulate the flow field, and the optimization design of the cathode can be guided according to the results of simulation.

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