scholarly journals The Effect of Electrolytic Jet Orientation on Machining Characteristics in Jet Electrochemical Machining

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 404 ◽  
Author(s):  
Xinmin Zhang ◽  
Xudong Song ◽  
Pingmei Ming ◽  
Xinchao Li ◽  
Yongbin Zeng ◽  
...  
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Horizontal Orientation ◽  
Jet Electrochemical Machining ◽  
Machining Characteristics ◽  
Machining Localization ◽  
Vertical Jet

Jet electrochemical machining (Jet-ECM) is a significant prospective electrochemical machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet machining, and the effect of jet orientations on machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of machining localization and a reduction of MMR for horizontal jet electrochemical machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve machining accuracy.

Enhancing the Surface Quality by Iso Pulse Generator in EDM Process

2012 ◽  
Vol 622-623 ◽  
pp. 380-384 ◽  
Author(s):  
T. Muthuramalingam ◽  
B. Mohan
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Discharge Energy ◽  
Crater Volume ◽  
Machining Characteristics ◽  
Edm Process

In automobile and aeronautical industries, complex moulds and dies is produced by Electrical Discharge Machining process. The surface finish is determined by the crater volume in EDM process. The amount of crater volume is influenced by the amount and distribution of discharge energy. The discharge energy is directly proportional to the average discharge current. This amount of current is determined by the duration of discharging effect. This study deals about evaluating the performance of iso current pulse generator on machining characteristics in EDM. Due to its ability of reducing stochastic nature in EDM process, iso pulse generator could produce better surface finish than conventional transistor pulse train generator with higher material removal rate.

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.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

MCDM Model for Selection of Optimum Machining Process

2013 ◽  
Vol 773-774 ◽  
pp. 348-354 ◽  
Author(s):  
Sriram Srinivasan ◽  
Lakshmikanthan Srivatsan ◽  
Rajaram Sathyanarayan ◽  
B. Vijaya Ramnath
Keyword(s):  
Automobile Industry ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Processes ◽  
Electric Discharge Machining ◽  
Analytical Hierarchical Process ◽  
Laser Beam Machining ◽  
Selection Of

The work of manufacturing engineers is to utilize the minimum amount of energy or resources in bringing out a product without compromising on quality. Hence, to achieve this, the engineers must figure out the optimum or the best possible method to fabricate a product. This paper uses a multi criteria decision making (MCDM) model namely Analytical Hierarchical Process (AHP) to determine the best possible machining process to achieve the optimum results for an engraving operation on gear face in an automobile industry which uses five nontraditional machining processes viz; Laser Beam Machining (LBM), Ultrasonic Machining (USM), Electric Discharge Machining (EDM), Electrochemical Machining (ECM) and Electron Beam Machining (EBM). The five criteria considered in this paper are Material Removal Rate (MRR), Surface Finish, Depth Damage, Tolerance and Toxicity. The AHP result shows that ECM is the most suitable machining process as compared to others.

Optimizing of Integral Impeller NC Program Based on the Material Removal Rate

2014 ◽  
Vol 1030-1032 ◽  
pp. 1305-1308
Author(s):  
Shi Chao Li ◽  
Song Lin Wu ◽  
Yan Kun Liang
Keyword(s):  
Material Removal Rate ◽  
Machine Tools ◽  
Material Removal ◽  
Removal Rate ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Accuracy ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Five Axis

It is a general processing technology that multi-axis NC machine tools is used for machining impeller at present. In order to improve the machining accuracy of the five-axis NC machine tools, the paper analyzes the computing interpolation error of the Multi-axis CNC system in detail. Some of the measures of tools selection have been proposed in purpose of diminishing the accumulative error of the system. The paper also establishes the optimized objective function to optimize the process parameters of the CNC machining based on the material removal rate. All these measures will improve the machining efficiency significantly and increase the stationary of the machining process.

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.

Modeling and Analysis Effects of Material Removal on Machining Dynamics in Milling of Thin-Walled Workpiece

2011 ◽  
Vol 223 ◽  
pp. 671-678 ◽  
Author(s):  
Ming Luo ◽  
Ding Hua Zhang ◽  
Bao Hai Wu ◽  
Ming Tang
Keyword(s):  
Material Removal ◽  
Dynamic Properties ◽  
Removal Rate ◽  
Milling Process ◽  
Machining Process ◽  
Machining Accuracy ◽  
Modeling And Analysis ◽  
Process System ◽  
Material Choice ◽  
Thin Walled

In aerospace industry, thin-walled workpieces are widely used in order to reduce the weight and to fulfill the high demands of their later applications. These workpieces are usually highly sophisticated and difficult to machine according to their geometry and material choice. In this paper, influence of material removal within the thin-walled workpiece machining operation on the dynamic properties of the workpiece and the machining process system is discussed. Aiming at learning about dynamic properties evolution during the machining operation, different milling processes of thin-walled plate are studied. Numerical simulation methods are employed in the study to investigate the dynamic properties evolution and machining stability with the material removal process in the milling process of thin-walled workpiece. The investigation results are expected to be used for designing optimized material removal sequence, which will guarantee highly material removal rate as well as highly machining accuracy of thin-walled workpiece.

scholarly journals Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
T. Praveena Gopinath ◽  
J. Prasanna ◽  
C. Chandrasekhara Sastry ◽  
Sandeep Patil
Keyword(s):  
Magnetic Field ◽  
Titanium Alloy ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Machining Accuracy ◽  
Micro Hole ◽  
Neodymium Magnets ◽  
Pulse On Time

Abstract An attempt has been made to study the influence of magnetic field on the micro hole machining of Ti-6Al-4V titanium alloy using electrochemical micromachining (ECMM) process. The presence of magneto hydro dynamics (MHD) is accomplished with the aid of external magnetic field (neodymium magnets) in order to improve the machining accuracy and the performance characteristics of ECMM. Close to ideal solution for magnetic and nonmagnetic field ECMM process, the parameters used are as follows: concentration electrolyte of 15 g/l; peak current of 1.35 A; pulse on time of 400 s; and duty factor of 0.5. An improvement of 11.91–52.43% and 23.51–129.68% in material removal rate (MRR) and 6.03–21.47% and 18.32–33.09% in overcut (OC) is observed in ECMM of titanium alloy under the influence of attraction and repulsion magnetic field, respectively, in correlation with nonmagnetic field ECMM process. A 55.34% surface roughness factor reduction is ascertained in the hole profile in magnetic field-ECMM in correlation with electrochemical machined titanium alloy under nonmagnetic field environment. No machining related stress is induced in the titanium alloy, even though environment of electrochemical machining process has been enhanced with the presence of magnetic field. A slight surge in the compressive residual factor, aids in surge of passivation potential of titanium alloy, resulting in higher resistance to outside environment.

Investigation of the Effects of Dielectric Inlet Pressure in Inner Jetted Dielectric EDM Milling

2011 ◽  
Vol 189-193 ◽  
pp. 125-128 ◽  
Author(s):  
Yan Qing Wang ◽  
Ji Cheng Bai ◽  
Yong Feng Guo ◽  
He Huang
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Great Influence ◽  
Machining Process ◽  
Inlet Pressure ◽  
Layer By Layer ◽  
Two Phase ◽  
Tool Wear Ratio ◽  
Discharge Gap ◽  
Machining Characteristics

In layer-by-layer EDM milling based on inner jetted dielectric, the dielectric inlet pressure is an important process parameter and has great influence on the machining characteristics. So, numerical simulation of the liquid-solid two-phase flow field in discharge gap is conducted. The simulation results of debris concentration reveal that the debris can be evacuated from the discharge gap in time, which increases the machining process stabilization and improves the machining efficiency. Finally, the effect of dielectric inlet pressure on material removal rate (MRR) and tool wear ratio (TWR) were also researched and discussed. The optimum inlet pressure, which maximized the MRR and minimized the TWR, was found through experiment.

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