The High Precision Blade Electrochemical Machining Simulation and Cathode Optimization Based on Isogeometric Method

2013 ◽  
Vol 339 ◽  
pp. 489-494 ◽  
Author(s):  
Ying Xiang ◽  
Rong Mo ◽  
Neng Wan ◽  
Hu Qiao
Keyword(s):  
Geometric Modeling ◽  
Design Method ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Simulation ◽  
Analysis Model ◽  
Simulation And Optimization ◽  
Nurbs Basis Function ◽  
Important Means ◽  
Optimization Efficiency

The simulation and optimization of electrochemical machining is an important means to improve processing quality. However, the fragmented nature of geometric modeling and numerical analysis model, restricts the application proportion. Aiming at this problem, it is refined that the scientific problem of coordination modeling between CAD and CAE based isogeometric method. In this paper, the unified model is established based NURBS basis functions to solve the problems that the geometric parameterization and the infliction of boundary conditions. And the optimization efficiency is promoted by improved optimization model using the convex hull characteristic of NURBS basis function. At last, a confluent design method is realized for the blade electrochemical machining process.

Experimental Investigation of a New Grid Cathode Design Method in Electrochemical Machining

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
Lu Yonghua ◽  
Zhao Dongbiao ◽  
Liu Kai
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Grid Cell ◽  
Machining Process ◽  
Cathode Design ◽  
Complex Shapes ◽  
Equivalent Area ◽  
Square Cells ◽  
Grid Cathode ◽  
Circular Grid

This paper focuses on the grid cathode design in electrochemical machining (ECM) in order to develop a new cathode design method for realizing a breakthrough: one cathode can produce different workpieces with different profiles. Three types of square cells, 2.5 mm × 2.5 mm, 3 mm × 3 mm, and 4 mm × 4 mm in size and three types of circular cells, with diameters of 1.5, 2.0, and 2.5 mm are utilized to construct the plane, slant, and blade grid cathode. The material of the cathode and anode is CrNi18Ti9 and the ingredients of the electrolyte are 15% NaCl and 15% NaNO3. A large number of experiments are conducted by using different grid cathodes to analyze the effects of the shape and size of the grid cell on the machining process. In addition, we compare the workpiece quality and machining error between using the grid cathode and the unitary cathode and discuss the reasons for the errors in order to obtain a better surface quality of the workpiece. Our research supports the conclusions that the grid cathode can be used to manufacture workpieces with complex shapes, the workpiece quality is better if the square cell is smaller and, for the same equivalent area, the circular grid cathode produces a better quality workpiece than the square grid cathode.

Research on Machining Simulation of Ultra High-Speed Grinding Machine Tool Based on Web

2010 ◽  
Vol 126-128 ◽  
pp. 77-81
Author(s):  
Wan Shan Wang ◽  
Peng Guan ◽  
Tian Biao Yu
Keyword(s):  
Machine Tool ◽  
Geometric Modeling ◽  
High Speed ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Simulation ◽  
Ultra High Speed ◽  
Cad Cam ◽  
High Speed Grinding ◽  
Grinding Machine

The future development of the manufacturing is using VR technology to make the machining simulation before the actual machining process made. The machining simulation of Ultra High-speed Grinding Machine Tool is researched in this paper. Firstly, using UG/NX software and VRML, the geometric modeling of machine tool is modeled. Secondly, through using Java and Javascript language, the operation and display of machining process of ultra high-speed grinding are realized. The main technologies include NC codes compiling, collision detection and material removal. Thirdly, the example of machining simulation using virtual ultra high-speed grinding machine tool can be obtained in the paper. Compared to other CNC machining simulation methods, the method in the paper has reality display, rich features, a good man-machine interaction, etc., and it does not rely on expensive CAD/CAM software. The system files generated by the machining simulation have the small size and can be transferred on the network easily.

The Effects of Normal Gap Distribution on Cathode Design of Aero-Engine Blades in Electrochemical Machining

2010 ◽  
Vol 97-101 ◽  
pp. 3583-3586 ◽  
Author(s):  
Zhi Yong Li ◽  
Hua Ji
Keyword(s):  
Design Method ◽  
Electrochemical Machining ◽  
Difficult Problem ◽  
Machining Process ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Three Dimension ◽  
Cathode Design ◽  
Aero Engine ◽  
Machining Rate

Cathode design is a difficult problem must be faced and solved in electrochemical machining (ECM). In ECM process, various parameters, such as applied voltage, current density, gap distribution, machining rate and electrolyte composition and concentration, can affect ECM machining process and therefore cathode design. Among all these machining parameters, gap distribution is the most vital. Regard some type of aero-engine compressor blade as research object, this paper concentrates on the effects of the normal gap distribution of 2-dimension and 3-dimension on cathode design based on the cathode design method of , moreover the errors between two and three dimension normal gap also can be compared and analyzed in detail. To verify the accuracy of the designed cathode, the machining experiments were conducted on an industrial scale ECM machine and the experimental results demonstrates that the cathode designed utilizing 3-dimension normal gap exhibits more machining accuracy and therefore valuable.

scholarly journals MODELLING OF THE OF ELECTROCHEMICAL MACHINING PROCESS

2007 ◽  
Vol 40 (18) ◽  
pp. 475-480
Author(s):  
Laurentiu SLATINEANU ◽  
Oana DODUN ◽  
Loredana SANTO ◽  
Margareta COTEATA ◽  
Adriana MUNTEANU
Keyword(s):  
Electrochemical Machining ◽  
Machining Process

Development of Machining Method for Micromold

2010 ◽  
Vol 154-155 ◽  
pp. 310-313
Author(s):  
Xue Feng Bi ◽  
Jin Sheng Wang ◽  
Jia Shun Shi ◽  
Ya Dong Gong
Keyword(s):  
Tool Path ◽  
Simulation Software ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Simulation ◽  
Post Process ◽  
Micro Parts ◽  
G Code ◽  
Micro Machine ◽  
3D Software

Micromold manufacturing technology is very important for the mass production of micro parts. In this paper, modeling of micromold is established in 3D software firstly. The 3D modeling is input into machining simulation software Master CAM to simulate machining process. The machining parameters and cutting tool path are optimized in machining simulation. Machining G code of micromold obtained from post-process program of Master CAM is input into HMI system of Micro Machine Tool (MMT), and hence the micromold will be machined precisely in MMT.

Analytical Method for Obtaining Cut Geometry of Helical Toroidal Cutter during Semi-Finish in 5-Axis Milling

2014 ◽  
Vol 541-542 ◽  
pp. 780-784 ◽  
Author(s):  
Gandjar Kiswanto ◽  
Hendriko Hendriko ◽  
Emmanuel Duc
Keyword(s):  
Analytical Method ◽  
Free Form ◽  
Machining Simulation ◽  
Tool Orientation ◽  
Essential Information ◽  
Simulation And Optimization ◽  
Helical Angle ◽  
Toroidal Cutter

Cut geometry data is an essential information in current machining simulation and optimization. The tool orientation changed continuously during free-form machining become a challenge in predicting cut geometry in 5-axis milling. This paper present an extended analytical method to define cut geometry during semi-finish milling. The algorithm was developed by taken into account the existence of helical angle. The developed model was successfully implemented to generate the shape and the length of cut. From the test it was found that helical angle gives significant effect to the cut geometry.

Application of Tree Graph Method for Reducing the Total Time of Tool Changing in Milling and Boring Machine Tools

2013 ◽  
Vol 371 ◽  
pp. 431-435 ◽  
Author(s):  
Claudiu Obreja ◽  
Gheorghe Stan ◽  
Lucian Adrian Mihaila ◽  
Marius Pascu
Keyword(s):  
Machine Tools ◽  
Design Method ◽  
Machining Process ◽  
Cnc Machine Tools ◽  
Tree Graph ◽  
Cnc Machine ◽  
High Productivity ◽  
Automatic Tool Changer ◽  
Automatic Tool ◽  
Set Up

With a view of increasing the productivity on CNC machine tools one of the main solution is to reduce, as much as possible, the auxiliary time consumed with the set-up and replacement of the tools and work pieces engaged in the machining process. Reducing the total time of the tool changing process by the automatic tool changer system can be also achieved through minimizing the number of movements needed for the actual exchange of the tool, from the tool magazine to the machine spindle (the optimization of the tool changing sequences). This paper presents a new design method based on the tree-graph theory. We consider an existing automatic tool changing system, mounted on the milling and boring machining centre, and by applying the new method we obtain all the possible configurations to minimize the tool changing sequence of the automatic tool changer system. By making use of the method proposed we obtain the tool changing sequences with minimum necessary movements needed to exchange the tool. Reconfiguring an existing machine tool provided with an automatic tool changer system by making use of the proposed method leads to obtaining the smallest changing time and thus high productivity.

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