scholarly journals Research on Multi-Physics Coupling Simulation for the Pulse Electrochemical Machining of Holes with Tube Electrodes

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 950
Author(s):  
Zhaolong Li ◽  
Bingren Cao ◽  
Ye Dai
Keyword(s):  
Current Density ◽  
Power Supply ◽  
Film Cooling ◽  
Simulation Analysis ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Inlet Pressure ◽  
Duty Ratio ◽  
Side Gap ◽  
Accuracy And Stability

Electrical parameters of the power supply are significant factors affecting the accuracy and stability of the electrochemical machining (ECM). However, the electric field, flow velocity and temperature in the machining area are difficult to measure directly under the influence of the power supply. Therefore, taking the film cooling hole as an example, the multi-physics coupling simulation analysis of the ECM is performed on the basis of Faraday’s law and fluid heat transfer mathematical model. The machining characteristics of the direct current and pulse ECM are compared through simulation. The results show that the pulse ECM improves the distribution of temperature and current density in the machining area. The period has little effect on the temperature, current density and side removal rate. The side removal rate increases with the increase of the duty ratio and lateral gap. Increasing of the duty ratio and decreasing of the lateral gap will increase the temperature and current density. Increasing the inlet pressure accelerates the frequency of renewal of heat and electrolysis products, which can reduce the single side gap. The experience of the ECM holes verifies the results of the simulation. The accuracy and stability of the ECM of holes are enhanced by optimizing the duty ratio, lateral gap and inlet pressure.

Research on Electrochemical Machining of Deep Small Holes with Positive and Negative Pulse Power

2021 ◽  
Vol 14 ◽  
Author(s):  
Zhaolong Li ◽  
Bingren Cao
Keyword(s):  
Power Supply ◽  
Pulse Width ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Negative Pulse ◽  
Mass Removal ◽  
Nickel Based Alloy ◽  
Accuracy And Stability ◽  
Small Holes

Background: High-temperature alloy such as nickel-based alloy has become the main material for core components such as aero engines due to their high strength and good toughness. Therefore, it is of great significance to study how to improve the machining accuracy and stability of electrochemical machining (ECM) of deep small holes on the nickel-based alloy. The instantaneous high-density current during the pulse width of pulse ECM is beneficial to the dissolution of metal workpieces. Many experts and scholars have studied the pulse ECM of deep small holes. Objective: The purpose of this article is to propose and design a Positive And Negative Pulse (PANP) power supply to study the accuracy and stability of ECM of deep small holes on nickel-based alloys. Methods: First of all, an H-bridge composed of four MOSFET switches is designed to achieve PANP output in the main circuit of the power supply. Then, this paper studies the influence of the ratio of positive and negative pulses on short circuits, the influence of the ratio of positive and negative pulses on the mass removal rate, and the influence of the electrolyte concentration and pulse width on the mass removal rate. Finally, according to the obtained optimal parameters, the influence of electrolyte pressure on the average radial overcut of hole depth is analyzed. Results: The experimental results showed that the short-circuit frequency is reduced by more than 50% compared with non-negative pulse power supply; the ratio of positive and negative pulses, pulse width and electrolyte concentration and pressure were optimized by experiments to improve the mass removal rate of the workpiece and the average radial overcut of hole depth. Conclusion: The designed PANP power supply can improve the machining accuracy and stability of ECM of deep small holes on nickel-based alloys.

Development of a Prototype of Electrochemical Machining

2011 ◽  
Vol 223 ◽  
pp. 940-949 ◽  
Author(s):  
Silva Neto ◽  
João Cirilo
Keyword(s):  
Power Supply ◽  
Material Removal ◽  
Metal Removal ◽  
State Of The Art ◽  
Removal Rate ◽  
Three Dimensional ◽  
Electrochemical Machining ◽  
Electrolytic Cell ◽  
Parameter Control ◽  
Purification System

Electrochemical machining (ECM) is the controlled removal of material by anodic dissolution in an electrolytic cell in which the workpiece is the anode and the tool is the cathode. The ECM presents the advantages: three-dimensional surfaces with complicated profiles can be easily machined in a single operation, irrespective of the hardness and strength of the material. ECM offers a higher rate of metal removal as compared to traditional and nontraditional methods, especially when high machining currents are employed. There is no wear of the tool, which permits repeatable production. This work shows a study of development of a prototype of electrochemical machining (ECM) developed at the Federal University of Uberlândia Minas Gerais-Brazil. A state-of-the-art ECM system is the art of assemblage of facilities including a proper ECM machine, a power supply, a process parameter control system, and an electrolyte preparation, feed and purification system. With the prototype developed, the material removal rate (MRR) was studied. The MRR was influenced by tool feed rate and type of electrolyte.

scholarly journals Study on the effect of electrocatalytic oxidation treatment of 2,4,6-Trinitrophenol wastewater

2018 ◽  
Vol 238 ◽  
pp. 03003
Author(s):  
Yaling Li ◽  
Wenqiang Jiang ◽  
Ruyu Li
Keyword(s):  
Current Density ◽  
Electrocatalytic Oxidation ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Pharmaceutical Chemical ◽  
Oxidation Treatment ◽  
Titanium Electrode ◽  
First Order Kinetics ◽  
Oxidation Technology ◽  
Aromatic Nitro

2,4,6-Trinitrophenol is a toxic aromatic nitro-compounds that widely used in pharmaceutical, chemical and pesticide production. Due to its stable structure and poor biodegradability, advanced electrocatalytic oxidation technology was selected to treat simulated wastewater. The goal of the present work is to optimize the electrolysis conditions such as current density, electrolysis pH, and electrolyte concentration. A Pt modified TiO2 electrode was chosen as the anode accompanied with a titanium electrode of the same size as the cathode The results showed that the removal efficiency of 2,4,6-Trinitrophenol was the highest when the current density was 20mA/cm2, electrolyte pH=5, electrolyte concentration was 2 g/L. Under the optimal condition, the removal rate of 2,4,6-Trinitrophenol reached 99.76% after 120 minutes electrolysis. The decay of TNP could also be described by the pseudo-first-order kinetics formula with respect to TNP concentration. Therefore, electrocatalytic oxidation technology might provide an effective method for the degradation of nitroaromatic organic compounds.

Influence of High Duty Ratio and Frequency in WECM Employing In Situ Fabricated Wire Electrode

2017 ◽  
Vol 5 (4) ◽  
Author(s):  
S. Debnath ◽  
J. Kundu ◽  
B. Bhattacharyya
Keyword(s):  
Mathematical Modeling ◽  
Electrochemical Machining ◽  
Burr Formation ◽  
Duty Ratio ◽  
Minimum Width ◽  
Applied Frequency ◽  
Early Adoption ◽  
Novel Approach ◽  
Microfabrication Techniques

To adapt with today's rapidly changing world, fabrication of intricate microparts is becoming an urgent need. Manufacturing of these microparts with stringent requirements necessitates the early adoption of different microfabrication techniques. Wire electrochemical machining (WECM) is such a process which removes excess metal by dissolving it electrochemically. This process can easily generate features downscaled to micron ranges and offers several advantages like the requirement of very simple setup, fabrication of accurate complex microfeatures without undergoing any thermal stress, burr formation, and tool wear, which make it superior from other existing micromachining processes. However, this process is new, and little is known about its applicability and feasibility. Hence, the present work is directed towards developing suitable WECM setup to fabricate microfeatures by introducing proper means for enhancing the mass transport phenomenon. The tungsten tool wire for machining has been in situ etched to a diameter of 23.43 μm by a novel approach for retaining its regular cylindrical form and has been implemented during machining. Moreover, the influences of high duty ratio and applied frequency have been investigated on the corresponding width of the fabricated microslits and the experimental results have been represented graphically where the minimum width of the microslit is obtained as 44.85 μm. Furthermore, mathematical modeling has been developed to correlate duty ratio and applied frequency with generated slit width. Additionally, the mathematical modeling has been validated with practical results and complex stepped type microfeatures have been generated to establish process suitability.

Effect of valency on material removal rate in electrochemical machining of aluminium

2008 ◽  
Vol 202 (1-3) ◽  
pp. 398-401 ◽  
Author(s):  
S.K. Mukherjee ◽  
S. Kumar ◽  
P.K. Srivastava ◽  
Arbind Kumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining

Removal of high concentration phenol from aqueous solutions by electrochemical technique

2021 ◽  
Vol 39 (2A) ◽  
pp. 189-195
Author(s):  
Shaimaa T. Alnasrawy ◽  
Ghayda Y. Alkindi ◽  
Taleb M. Albayati
Keyword(s):  
Current Density ◽  
Electrochemical Cell ◽  
Removal Rate ◽  
Electrochemical Process ◽  
Phenol Concentration ◽  
Electrochemical Technique ◽  
Process Conditions ◽  
Electrolysis Time ◽  
High Concentration ◽  
Maximum Removal

In this study, the ability of the electrochemical process to remove aqueous high concentration phenol using an electrochemical cell with aluminum anode and cathode was examined. The removal rate of phenol was monitored using different parameters phenol concentration, pH, electrolysis time, current density, and electrode distance. Obtained results indicated that the low removal rates of phenol were observed at both low and high pH. However, the removal rate of phenol increased with an increase in the current density, each electrochemical process conditions need a certain electrodes distance. removal rate of phenol decreased with the increase in the initial phenol concentration. The maximum removal rate of phenol obtained from this study was 82%.

scholarly journals Removal of the Rhodamine B Dye at Ti/Ru0.3Ti0.7O2 Anode Using Flow Cell System

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Ali Baddouh ◽  
Brahim El Ibrahimi ◽  
Elhassan Amaterz ◽  
M. Mohamed Rguiti ◽  
Lahcen Bazzi ◽  
...  
Keyword(s):  
Current Density ◽  
Rhodamine B ◽  
Removal Rate ◽  
Flow Cell ◽  
Cell System ◽  
Cod Removal ◽  
Color Removal ◽  
Ion Concentration ◽  
Applied Current ◽  
Rhodamine B Dye

The electrochemical oxidation of the Rhodamine B dye (Rh-B) was carried out using dimensionally stable type anode (DSA, Ti/Ru0.3Ti0.7O2). The work was performed using the electrochemical flow cell system. The effect of several operating factors, such as supporting electrolytes, current density, electrolysis time, temperature, and initial concentration of Rh-B dye, were investigated. The UV-visible spectroscopy and chemical oxygen demand (COD) measurements were conducted to monitor the removal and degradation of Rh-B. The best color removal achieved was found to be 98.3% after 10 min applying 3.9 mA·cm−2 as a current density using 0.07 mol·L−1 of NaCl. Meanwhile, the highest COD removal rate (93.0%) was obtained for an applied current density of 3.9 mA·cm−2 as the optimal operating condition after 180 min reaction time, with 2.98 kW h·m−3 as energy consumption. This shows that the best conditions for color removal are not certainly the same as those for the COD removal. The rises in the concentration of NaCl, and applied current increased the Rh-B color removal rate. The decline in Rh-B dye concentration followed pseudo-first-order kinetics. The obtained values of apparent rate constant were increased by increasing chloride ion concentration. It is concluded that the electro-oxidation on DSA electrode using a flow cell is a suitable process for the removal of Rh-B dye in aqueous solutions.

Removing As, Ba, Cu and Zn from Waste Plasma Display Panel Glass by Electrokinetics

2014 ◽  
Vol 878 ◽  
pp. 393-398
Author(s):  
Meng Jun Chen ◽  
Oladele A. Ogunseitan
Keyword(s):  
Heavy Metal ◽  
Current Density ◽  
Removal Rate ◽  
Rapid Development ◽  
Anode Chamber ◽  
Flat Panel Display ◽  
Plasma Display Panel ◽  
Plasma Display ◽  
Middle Chamber ◽  
Cu And Zn

Due to shorter and shorter life span and the rapid development of flat panel display, plasma display panel (PDP) is now becoming a new kind of e-waste. In order to remove heavy metals, such as As, Ba, Cu, Zn, from waste PDP glass, electro-kinetic process was introduced and factors that affect heavy metal removing rate were investigated. Results showed that HNO3 concentration and PDP adding amount could significantly impact heavy metal removing rate, while current density was on the opposite. Heavy metal removing rate increased first and then decreased as the time extension. When PDP powders was 2 g, 9 mL 5 mol/L HNO3 was added, current density was 200 mA/cm2 and time was 6 h, the removal rate of As, Ba, Cu, Zn were 71.02%, 95.87%, 92.50% and 97.70%, respectively. As, Ba, Cu and Zn distributions in the cathode, anode and middle chamber varied as changing particle size, HNO3 concentration, current density. Generally, most Cu was concentrated in cathode chamber, and Zn in the anode chamber, while As and Ba would be in both cathode and anode chamber. As, Ba, Cu and Zn, in the middle chamber, no more than 10%, were the lowest among the three.

The Application and Research of Electrochemical Method Treating Acid Red 3R Simulation Wastewater by Response Surface Method

2013 ◽  
Vol 295-298 ◽  
pp. 1258-1262
Author(s):  
Jun Sheng Hu ◽  
Lei Guan ◽  
Jia Li Dong ◽  
Ying Wang ◽  
Ying Yong Duan
Keyword(s):  
Response Surface ◽  
Electrochemical Oxidation ◽  
Current Density ◽  
Electrochemical Method ◽  
Electrolyte Concentration ◽  
Ph Value ◽  
Removal Rate ◽  
Oxidation Method ◽  
Surface Method ◽  
Optimal Value

Using electrochemical oxidation method treats the acid red 3R simulation wastewater, investigates the influence of current density, electrolyte concentration, pH-value and aeration and their interaction on the removal rate of chroma. Through the design of Box-Benhnken Design(BBD) and the response surface analysis, the influence sequence of all variables is current density > aeration > electrolyte concentration > pH-value, the influence sequence of all interaction is electrolyte concentration-aeration > current density-aeration ,electrolyte concentration-pH value > current density-pH value > pH value-aeration > current density-electrolyte concentration. Ultimately, the optimal value is 98.4915% under the condition of current density of 6.51mA/cm2,electrolyte concentration of 0.04mol/L,pH-value of 4.17 and aeration of 0.24m3/h.

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