scholarly journals Multi-Physics Coupling Modeling and Experimental Investigation of Vibration-Assisted Blisk Channel ECM

Micromachines ◽  
2021 ◽  
Vol 13 (1) ◽  
pp. 50
Author(s):  
Juchen Zhang ◽  
Shasha Song ◽  
Junsheng Zhang ◽  
Weijie Chang ◽  
Haidong Yang ◽  
...  
Keyword(s):  
Flow Field ◽  
Surface Quality ◽  
Complex Structure ◽  
Electrochemical Machining ◽  
Coupling Model ◽  
Two Phase ◽  
Field Coupling ◽  
Good Surface ◽  
Material Hardness ◽  
Relative Errors

Due to its advantages of good surface quality and not being affected by material hardness, electrochemical machining (ECM) is suitable for the machining of blisk, which is known for its hard-to-machine materials and complex shapes. However, because of the unstable processing and low machining quality, conventional linear feeding blisk ECM has difficulty in obtaining a complex structure. To settle this problem, the vibration-assisted ECM method is introduced to machine blisk channels in this paper. To analyze the influence of vibration on the process of ECM, a two-phase flow field model is established based on the RANS k-ε turbulence model, which is suitable for narrow flow field and high flow velocity. The model is coupled with the electric field, the flow field, and the temperature field to form a multi-physics field coupling model. In addition, dynamic simulation is carried out on account of the multi-physics field coupling model and comparative experiments are conducted using the self-developed ECM machine tool. While a shortcut appeared in the contrast experiment, machining with vibration-assisted channel ECM achieved fine machining stability and surface quality. The workpiece obtained by vibration-assisted channel ECM has three narrow and straight channels, with a width of less than 3 mm, an aspect ratio of more than 8, and an average surface roughness Ra in the hub of 0.327 μm. Compared with experimental data, the maximum relative errors of simulation are only 1.05% in channel width and 8.11% in machining current, which indicates that the multi-physics field coupling model is close to machining reality.

Design and Analysis of Flow Field in Electrochemical Cutting Processing by Arranged Tube Electrode

2017 ◽  
Vol 872 ◽  
pp. 67-76
Author(s):  
Jun Yao ◽  
Yu Jun Nie ◽  
Zhi Tong Chen
Keyword(s):  
Flow Field ◽  
High Efficiency ◽  
Short Circuit ◽  
Complex Structure ◽  
Electrochemical Machining ◽  
Utilization Rate ◽  
Processing Efficiency ◽  
Machine Material ◽  
Tube Electrode ◽  
The Cost

The large complex structure integral components composed of difficult-to-machine material (such as titanium alloy, high temperature alloy) are more and more widely applied in aerospace, weapon equipment and other industries. The material utilization rate and the processing efficiency of the milling process are very low, the cost is high. Micro copper tubes (diameter 2mm, inner diameter 1.6mm) are arranged to electrode with shape to be processed, which could cut these components with a high efficiency and low cost. The fabrication of electrode is simple and convenient, so the cost of electrode could be reduced too. The flow field design is an important problem to be solved. The model of flow field is established, and flow field of different cathodes are simulated．The analysis results show that the rectifying ring is favorable for the electrochemical machining. Finally, the cathode with rectifying ring is used in processing experiment, the edge of cutting zone is orderly, no spark and short circuit occurs. Straight line and circular hole is successfully processed. The feasibility of the scheme is proved.

scholarly journals Electrochemical machining gap prediction with multi-physics coupling model based on two-phase turbulence flow

2020 ◽  
Vol 33 (3) ◽  
pp. 1057-1063
Author(s):  
Yuanlong CHEN ◽  
Xiaochao ZHOU ◽  
Peixuan CHEN ◽  
Ziquan WANG
Keyword(s):  
Electrochemical Machining ◽  
Coupling Model ◽  
Two Phase ◽  
Model Based ◽  
Turbulence Flow

Flow field design and experimental study of electrochemical machining using thin hollow cathodes

2018 ◽  
Vol 233 (3) ◽  
pp. 766-775 ◽  
Author(s):  
Jun Yao ◽  
Zhi-Tong Chen ◽  
Yu-Jun Nie ◽  
Feng Wang
Keyword(s):  
Numerical Analysis ◽  
Flow Field ◽  
Removal Rate ◽  
Complex Structure ◽  
Electrochemical Machining ◽  
High Strength ◽  
Machining Efficiency ◽  
Hollow Cathodes ◽  
Cathode Structure ◽  
Flow Field Design

In order to pursue excellent performance, especially in aerospace and weapon equipment industry, components with complex structure made of difficult-to-cut material (stainless steel, titanium alloy, high-temperature alloy etc.) are more and more applied. From the rough to the finished product, the material removal rate (ranging from 10% to 90%) may be large, the machining efficiency and material utilization are low, and the machining cost would be high using traditional milling or grinding method. One kind of thin hollow cathode having high strength is developed for electrochemical machining of complex structure. This cathode is expected to improve the machining efficiency and reduce the cost. The flow field design is a key problem to be solved. Fluid dynamics numerical analysis is used to optimize the cathode structure, and the design rules of cathode are given. Experiments are carried out to prove the correctness of the numerical analysis, cutting stability, accuracy, and surface quality are improved. Finally, different structures are successfully machined on the material of TB6 by thin hollow cathodes.

Simulation Research of Small Holes by Combined Ultrasonic and Electrochemical Machining Based on CFX

2013 ◽  
Vol 584 ◽  
pp. 60-66 ◽  
Author(s):  
Ze Xiang Liu ◽  
Min Kang ◽  
Xiu Qing Fu
Keyword(s):  
Flow Field ◽  
Three Dimensional ◽  
Electrochemical Machining ◽  
Dimensional Model ◽  
Three Dimensional Model ◽  
Two Phase ◽  
Simulation Research ◽  
Ansys Cfx ◽  
Phase Fluid ◽  
Small Holes

A device was designed to study the small holes by the rotary combined ultrasonic and electrochemical machining, and the gap between cathode and anode in the processing was also analyzed. A three-dimensional model of flow field was developed in ANSYS CFX software based on FEM by the gas-liquid two-phase fluid cavitations model as well as the effect of rotary cathode and the vibrated cathode to the flow field was analyzed. The simulation showed that the pressure and the velocity of the electrolyte in the gap were oscillated by additional motion of cathode, which is helpful to the electrochemical machining. The comparison of rotary electrochemical machining and the rotary combined ultrasonic and electrochemical machining showed that the rotary combined ultrasonic and electrochemical machining has better ability of making small holes than that of rotary electrochemical machining

scholarly journals Experimental Research on Machining Localization and Surface Quality in Micro Electrochemical Milling of Nickel-Based Superalloy

Micromachines ◽  
2018 ◽  
Vol 9 (8) ◽  
pp. 402 ◽  
Author(s):  
Yong Liu ◽  
Yong Jiang ◽  
Chunsheng Guo ◽  
Shihui Deng ◽  
Huanghai Kong
Keyword(s):  
Surface Quality ◽  
Electrochemical Machining ◽  
Nanosecond Pulse ◽  
Machining Parameters ◽  
Pulse Technique ◽  
Nickel Based Superalloy ◽  
Good Surface ◽  
Pulse On Time ◽  
Electrochemical Milling ◽  
Machining Localization

Micro electrochemical machining is becoming increasingly important in the microfabrication of metal parts. In this paper, the machining characteristics of micro electrochemical milling with nanosecond pulse were studied. Firstly, a mathematical model for the localization control of micro electrochemical milling with nanosecond pulse was established. Secondly, groups of experiments were conducted on nickel-based superalloy and the effects of parameters such as applied voltage, pulse on time, pulse period, electrolyte concentration and electrode diameter on machining localization and surface roughness were analyzed. Finally, by using the optimized machining parameters, some 2D complex shapes and 3D square cavity structures with good shape precision and good surface quality were successfully obtained. It was proved that the micro electrochemical milling with nanosecond pulse technique is an effective machining method to fabricate metal microstructures.

ANALYSIS OF THE ACCURACY OF ELECTROMECHANICAL MICROMACHINING

2020 ◽  
pp. 60-64
Author(s):  
Yu.A. Morgunov ◽  
B.P. Saushkin ◽  
N.V. Homyakova
Keyword(s):  
Electrochemical Performance ◽  
Electrochemical Machining ◽  
Machining Error ◽  
Processing Mode ◽  
Primary Error ◽  
Flow Through ◽  
Relative Errors ◽  
Size Tolerance

The achieved accuracy in the electrochemical performance of understatement with a depth of 18 mcm with a tolerance of 4.5 mcm in a flow-through interelectrode channel is studied. The primary error of the size. The allowed absolute and relative errors of processing mode parameters are set. Keywords: UNDERSTATEMENT, ELECTROCHEMICAL MACHINING, ERROR, PRECISION SIZE, TOLERANCE, PROCESSING MODE. [email protected]

Status of Advanced Two-Phase Flow Model Development for SRM Chamber Flow Field and Combustion Modeling

2004 ◽  
Author(s):  
Gary Luke ◽  
Mark Eagar ◽  
Michael Sears ◽  
Scott Felt ◽  
Bob Prozan
Keyword(s):  
Flow Field ◽  
Flow Model ◽  
Two Phase Flow ◽  
Model Development ◽  
Phase Flow ◽  
Two Phase ◽  
Combustion Modeling

Predicting the number of fiber roots in lola drafting based on multi-field coupling

2020 ◽  
Vol 90 (23-24) ◽  
pp. 2769-2781
Author(s):  
Xin rong Li ◽  
LiuBo Wu ◽  
Zhaoning Bu ◽  
Lidong Liu
Keyword(s):  
Change Point ◽  
Production Efficiency ◽  
Slip Rate ◽  
Sharp Decrease ◽  
Coupling Model ◽  
Production Costs ◽  
Weak Effect ◽  
Field Coupling ◽  
Theoretical Support ◽  
New Type

Pullout theory is very important in improving efficiency, quality, and production costs. Because production efficiency is too low for mechanical drafting equipment, a simple multi-field coupling model of fiber mechanics based on conserving momentum is proposed that considers the distribution of the fiber speed point, slip rate, and friction mechanics. When the roller draft multiple is increased, the position near the rear roller clamp mouth in the draft area will show a sharp decrease of fiber, which is caused by the rapid movement of the front fiber to drive the floating fiber movement, and it is also the existence of the fiber change point. When the roller spacing increases, the draft efficiency decreases, although the pressure applied by the roller to the fibrous strip has a weak effect on the draft efficiency. This research increases our understanding of drawing and provides theoretical support for the design of a new type of drawing.

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