Fundamental Experimental Study on Numerical-Control Electrochemical Finish Machining for Integral Impeller Blade

2011 ◽  
Vol 55-57 ◽  
pp. 1275-1280 ◽  
Author(s):  
Jian Min Wu ◽  
Jia Wen Xu
Keyword(s):  
Electrochemical Machining ◽  
Normal Direction ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Blade Surface ◽  
Electrode Gap ◽  
Impeller Blade ◽  
Finish Machining

While the surface of integral impeller blade was electrochemically machined, cathode cannot rotate in accordance with other movement axes, which results in nonuniformity in velocity of electrolyte and normal direction of the machining blade surface, thereby causing inaccuracy in the machined blade surface. In order to solve this problem, the shaping law was studied in Electrochemical Finish Machining. Then relative positions between cathode slot and blade surface were analyzed during the process of Electrochemical Machining (ECM). Three parameters, namely feed direction, feed velocity and initial machining inter-electrode gap, were adjusted to conduct the fundamental experiments when direction of cathode slot was changed. Afterwards machining accuracy as well as surface quality of workpiece was analyzed. Finally according to experimental results, direction of cathode slot was determined practically in electrochemical machining process and the integral impeller blades meeting the requirement were electrochemically machined.

scholarly journals Electrochemical machining – state of the art and direction of development

Mechanik ◽  
2017 ◽  
Vol 90 (12) ◽  
pp. 1102-1109
Author(s):  
Adam Ruszaj
Keyword(s):  
Material Removal ◽  
Cathode Surface ◽  
Hydrogen Generation ◽  
Electrochemical Machining ◽  
Electrical Current ◽  
Machining Process ◽  
Advanced Materials ◽  
Electrode Gap ◽  
Machined Surface

Electrochemical machining process (ECM) can be applied for efficient shaping advanced materials conducting electrical current, which are difficult or impossible for machining using conventional methods. In electrochemical machining, the workpiece is an anode and material is removed as a result of electrochemical reactions “atom by atom” without mechanical forces. This mechanism of material removal make it possible to obtain high quality of machined surface layer with uniform properties. The very important advantage of ECM process is also the fact that there is not a tool wear (working electrode – cathode), because the equivalent reaction to anodic dissolution is hydrogen generation on cathode surface and hydrogen can be easily removed from, the inter-electrode gap by electrolyte flow. Because of this advantages, the ECM process is widely applied in space, aircraft, car and electromechanical industry and research stimulating ECM development are carried out.

Improvement of leading-edge accuracy by optimizing the cathode design plane in electrochemical machining of a twisted blade

2019 ◽  
Vol 234 (4) ◽  
pp. 814-824 ◽  
Author(s):  
Lingguo Yu ◽  
Dong Zhu ◽  
Yujun Yang ◽  
Jibin Zhao
Keyword(s):  
Three Dimensional ◽  
Electrochemical Machining ◽  
Leading Edge ◽  
The Body ◽  
Machining Process ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Cathode Design ◽  
Twisted Blade ◽  
Blade Leading Edge

Cathode design plays an important role in the electrochemical machining of aero engine blades and is a core issue influencing machining accuracy. Precision electrochemical machining of the leading edge of a twisted blade is particularly difficult. To improve the electrochemical machining accuracy of the leading edge, this article deals with cathode design by optimizing the design plane based on the three-dimensional potential distribution in the inter-electrode gap. A mathematical model is established according to the electrochemical machining shaping law, and the formation of the blade leading edge is simulated using ANSYS. The simulation results show that the blade leading-edge profile obtained with the optimized planar cathode is more consistent with the blade model profile. The optimized planar cathode and a non-optimized planar cathode are designed and a series of corresponding electrochemical machining experiments is carried out. The experiments show that the electrochemical machining process is stable and that the surface quality near the leading edge of the samples is slightly better than that of the body surface. Compared with the non-optimized planar cathode, the allowance difference at the leading-edge vertex is decreased by 0.062 mm. Using the optimized planar cathode allows fabrication of a workpiece whose shape is similar to that of the designed twisted blade.

scholarly journals Research on Stagger Coupling Mode of Pulse Duration and Tool Vibration in Electrochemical Machining

2018 ◽  
Vol 8 (8) ◽  
pp. 1296 ◽  
Author(s):  
Xiaochen Jiang ◽  
Jia Liu ◽  
Di Zhu ◽  
Mingming Wang ◽  
Ningsong Qu
Keyword(s):  
Pulse Duration ◽  
Feed Rate ◽  
Electrochemical Machining ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Tool Vibration ◽  
Coupling Mode ◽  
Machining Localization ◽  
Electrolysis Products ◽  
Gas Void Fraction

Tuning the coupling of pulse duration and tool vibration in electrochemical machining (PVECM) is an effective method to improve machining accuracy and surface quality. In general, the pulse is set at the same frequency as the tool vibration, and a symmetrical distribution is attained at the minimum inter-electrode gap. To analyse the characteristics of the electrolyte fluid flow and of the electrolysis products in the oscillating inter-electrode gap, a dynamic simulation of the PVECM process was carried out. The simulation results indicated that the electrolyte pressure and gas void fraction when the pulse arrived as the inter-electrode gap was narrowing clearly differed from those when the inter-electrode gap was expanding. Therefore, in addition to the traditional symmetry coupling mode, two other coupling modes called the pre-position and the post-position coupling modes are proposed which use a pulse either just before or just after the minimum inter-electrode gap. Comparative experiments involving the feed rate and machining localization were carried out to evaluate the influence of the three coupling modes. In addition, current waveforms were recorded to analyse the differences between the three coupling modes. The results revealed that the highest feed rate and the best machining localization were achieved by using the pre-position coupling mode.

scholarly journals Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

Coatings ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 590
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
Tomas Prokes ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Cutting Speed ◽  
Machining Process ◽  
Precision Machining ◽  
Machining Accuracy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Super Alloy ◽  
Machined Surfaces

Wire electrical discharge machining (WEDM) is an unconventional and very efficient technology for precision machining of the Nimonic C 263 super alloy, which is very widespread, especially in the energy, aerospace and automotive industries. Due to electrical discharge, defects in the form of cracks or burned cavities often occur on the machined surfaces, which negatively affect the correct functionality and service life of the manufactured components. To increase the efficiency of the machining of Nimonic C 263 using WEDM, in this study, extensive design of experiments was carried out, monitoring input factors in the form of machine parameters like Pulse off time, Gap voltage, Discharge current, Pulse on time and Wire feed, the output of which was comprehensive information about the behaviour of such machined surfaces, which allowed the optimization of the entire machining process. Thus, the optimization of the Cutting speed was performed in relation to the quality of the machined surface and the machining accuracy, as well as an analysis of the chemical composition of the machined surfaces and a detailed analysis of the lamella using a transmission electron microscope. A detailed study of the occurrence of surface or subsurface defects was also included. It was found that with the help of complex optimization tools, it is possible to significantly increase the efficiency of the machining of the Nimonic C 263 super alloy and achieve both financial savings in the form of shortened machine time and increasing the quality of machined surfaces.

Synchronous Adjustment of Milling Tool Path Based on the Relative Deviation

2011 ◽  
Vol 133 (5) ◽  
Author(s):  
Xiao-Jin Wan ◽  
Cai-Hua Xiong ◽  
Lin Hua
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Source File ◽  
Modern Computer ◽  
Adjustment Strategy ◽  
Machining System

In machining process, machining accuracy of part mainly depends on the position and orientation of the cutting tool with respect to the workpiece which is influenced by errors of machine tools and cutter-workpiece-fixture system. A systematic modeling method is presented to integrate the two types of error sources into the deviation of the cutting tool relative to the workpiece which determines the accuracy of the machining system. For the purpose of minimizing the machining error, an adjustment strategy of tool path is proposed on the basis of the generation principle of the cutter location source file (CLSF) in modern computer aided manufacturing (CAM) system by means of the prediction deviation, namely, the deviation of the cutting tool relative to the workpiece in computer numerical control (CNC) machining operation. The resulting errors are introduced as adjustment values to adjust the nominal tool path points from cutter location source file from commercial CAM system prior to machining. Finally, this paper demonstrates the effectiveness of the prediction model and the adjustment technique by two study cases.

Quality assurance for concave-arc ball-end milling cutters

2003 ◽  
Vol 217 (2) ◽  
pp. 181-191 ◽  
Author(s):  
W-F Chen ◽  
H-Y Lai ◽  
C-K Chen
Keyword(s):  
End Milling ◽  
Spherical Surface ◽  
Numerical Control ◽  
Machining Accuracy ◽  
Milling Cutter ◽  
Modelling Procedure ◽  
Profile Errors ◽  
Complicated Surface ◽  
Dies And Moulds

This paper presents a systematic modelling procedure for assessing the profile quality of concave-arc ball-end (CABE) milling cutters with a cylindrical shank. CABE milling cutters are widely used in three-axis numerical control (NC) machines for producing dies and moulds of complicated surface features. Evaluation of the contour quality of the CABE milling cutter is crucial in enhancing machining accuracy and efficiency. In order adequately to describe the shape of the clamped cutter, the centre-line axis of the minimum circumscribed cylinder of the cylinder shank is taken as the referenced datum axis. The minimum circumscribed concave-arc revolving surface and the minimum circumscribed spherical surface are carefully derived in sequence. The profile errors and tolerances are estimated. The quality of the CABE milling cutter is assured by using the proposed modelling procedure, and several numerical examples are presented to illustrate its effectiveness. The results indicate that the present method is feasible and can be extended to enhance the quality of various revolving cutters.

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.

Experimental Investigation of Cut Profile in the Electrochemical Drilling of Titanium Alloy

2018 ◽  
Vol 777 ◽  
pp. 327-332
Author(s):  
Ornsurang Netprasert ◽  
Noppakao Chimyo ◽  
Suphaphich Phimphun ◽  
Jantakarn Sukjan ◽  
Viboon Tangwarodomnukun ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Applied Voltage ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Experimental Result ◽  
Drilling Process ◽  
Electrode Gap ◽  
Electrochemical Drilling ◽  
Cut Quality

Electrochemical machining process is an advanced material removal technique offering high precision and introducing no heat damage to the work material. The shape and size of machined area are highly dependent on some process parameters such as voltage, electrolyte and inter-electrode gap. To further enable a more insight into the process performance, this paper investigates the influences of applied voltage, electrolyte concentration and inter-electrode gap on the shape and sizes of hole produced by the electrochemical drilling process. Titanium alloy (Ti-6Al-4V) was used as a work sample in this study as it has been extensively used in many advanced applications. The experimental result indicated that the use of high voltage and high electrolyte concentration can enlarge and deepen hole in the workpiece, while the inter-electrode gap provided less effect to the hole features. The maximum hole depth can reach 300 μm within 60 seconds when the applied voltage of 30 V, the inter-electrode gap of 10 μm and the electrolyte concentration of 10%wt were used. However, with this setup, the obtained cut profile became a non-uniform V-shaped hole. The use of lower voltage was instead recommended to yield a better cut quality with U-shaped profile.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

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.

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