Research on the Process Simulation of NC-ECM with Ball-End Tool-Electrode

2010 ◽  
Vol 154-155 ◽  
pp. 338-343
Author(s):  
Min Kang ◽  
Xiu Qing Fu ◽  
Yong Yang
Keyword(s):  
Process Simulation ◽  
Electrochemical Machining ◽  
Current Density Distribution ◽  
Simulation Method ◽  
Difficult Problem ◽  
Numerical Control ◽  
Surface Shape ◽  
Tool Electrode ◽  
Analysis Model ◽  
Machined Surface

In order to solve the difficult problem in analyzing the shaping law of numerical control electrochemical machining (NC-ECM) with ball-end cathode, the process simulation based on the finite element method (FEM) is used in this paper. First, the two-dimensional analysis model of the electric field in NC-ECM with ball-end tool-electrode built by use of ANSYS software was solved, and the current density distribution and the machined surface shape on the workpiece were obtained. Then, the experiments based on the simulation parameters were carried out, and the cutting depth values were measured. Finally, the accuracy of the simulation was verified by the comparison between the calculated values and the actual values. The experiments showed that the simulation method meets the accuracy of the engineering calculations in NC-ECM.

Research on the Process of NC-ECM with Ball-End Cathode Based on FEM

2010 ◽  
Vol 458 ◽  
pp. 93-98 ◽  
Author(s):  
Yong Yang ◽  
Min Kang ◽  
Xiu Qing Fu
Keyword(s):  
Finite Element Method ◽  
Process Simulation ◽  
Current Density Distribution ◽  
Simulation Method ◽  
Surface Shape ◽  
Two Dimensional ◽  
The Finite Element Method ◽  
Analysis Model ◽  
Ansys Software ◽  
Simulation Parameters

In order to solve the difficulty in analyzing the shaping law of NC-ECM with ball-end cathode, the method of processing simulation was presented based on the finite element method (FEM). The two-dimensional analysis model of the electric field with ball-end cathode built in ANSYS software was solved. The current density distribution and surface shape in different time on the anode were obtained. The experiments based on the simulation parameters were carried out, and the dimensions of the processed surface were measured, which were compared with the theoretical values. It is indicated that the simulation method meets the accuracy of the engineering calculations. The method and theory for further in-depth research on the process simulation in NC-ECM with ball-end cathode are provided.

Research on the Process of Numerical Control Electrochemical Turning Based on Finite Element Method

2013 ◽  
Vol 764 ◽  
pp. 95-101 ◽  
Author(s):  
Xiu Qing Fu ◽  
Jie Yu Xian ◽  
Min Kang ◽  
Mao Hua Xiao
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Three Dimensional ◽  
Current Density Distribution ◽  
Simulation Method ◽  
Numerical Control ◽  
Percentage Error ◽  
Analysis Model ◽  
Electrochemical Turning ◽  
Element Method

The processing simulation method of numerical control electrochemical turning (NC-ECT) was presented based on the finite element method (FEM) in this paper. The three-dimensional analysis model of the electric field built in ANSYS software was solved. The current density distribution and the theoretical values of material removed depth per revolution (MRDPR) in different time on the anode were obtained. The experiments were carried out on the NC-ECT lathe, and the measured values of MRDPR were measured, which were compared with the theoretical values. It is indicated that the maximum percentage error between the theoretical values and the measured values is smaller and the simulation method meets the accuracy of the engineering calculations.

NC-Electrochemical Contour Evolution Machining for Globoidal Indexing Cam

2010 ◽  
Vol 37-38 ◽  
pp. 702-705
Author(s):  
Xue Fei Tang ◽  
Wei He
Keyword(s):  
Electrochemical Machining ◽  
Negative Electrode ◽  
Numerical Control ◽  
Tool Electrode ◽  
Numerical Control Machining ◽  
Procedure Code ◽  
Machining System ◽  
Contour Evolution ◽  
Moving Path

The NC-electrochemical contour evolution machining for globoidal indexing cam was proposed. The principle of electrochemical machining with inter injection cylindrical tool electrode and the composition of the machining system was introduced. The algorithm to determine negative electrode enveloping moving path may generate the NC procedure code used for numerical control machining directly.

Primary Research on Jet ECM Processing of Difficult to Cut Materials

2013 ◽  
Vol 554-557 ◽  
pp. 1793-1799 ◽  
Author(s):  
Piotr Lipiec ◽  
Dominik Wyszynski ◽  
Sebastian Skoczypiec
Keyword(s):  
Current Density ◽  
Large Scale ◽  
Electrochemical Machining ◽  
Current Density Distribution ◽  
Electrochemical Process ◽  
Experiment Planning ◽  
Work Piece ◽  
Machined Surface ◽  
Jet Electrochemical Machining ◽  
Electrolyte Jet

Unconventional production techniques became interesting and promising part of manufacturing methods. They provide complementary, to traditional loss methods, solutions enabling use of high - performance engineering materials for construction of machinery and industrial equipment. By using properly selected methods or their hybrids difficult to cut materials as steel, alloys, sintered materials and composites can be processed. Among the wide variety of unconventional methods of materials forming, particular attention should be given to electrochemical machining, which has been successfully used in various industries. This fact proves attractiveness and versatility of ECM. The method could be used on large scale and many variations was developed as each application requires an individual approach and has own requirements. One of the least known and described type of electrochemical machining is jet ECM where the electrolyte jet stream acts as a tool. In this kind of machining, the part is shaped only in the area where the electrolyte jet strikes the surface. This is due to the fact that the current density distribution is located just below the stream. In the area around the jet hitting the work piece thin electrolyte layer is formed. Thickness of that layer is growing rapidly. Since the electrolyte jet machining is an electrochemical process, the machined surface has all the benefits of ECM. There is no burrs and low temperature of the process prevents appearance of cracks and there is no heat-affected zone. Electrolyte jet machining can be used as well as in macro and micro drilling, turning, texturing, and electroplating. The process can be controlled by proper selection of such parameters as time, the current density and the diameter of the jet. Jet ECM can be used not only for material removal, but also for coloration (passivation) by means of anodic dissolution. 3D shaping of elements is also possible by controlling the current and the velocity of the electrolyte stream. In addition, by changing the polarity of the applied voltage it is possible to use this method in broadly considered electroplating. The paper presents results of the initial research on jet electrochemical machining (jet ECM) of acid proof steel and tungsten carbide. The material processing was carried in two ways – drilling holes and shaping grooves. Shaping was realized in milling and face turning regime. The influence of the two basic process parameters voltage and pressure was examined. In order to get rough information about the jet ECM process experiment planning method was applied. Obtained results enable planning of the further extended research.

Improving Performance of Laser and Shaped Tube Electrochemical Machining by Using Retracted Hybrid Tubular Tool Electrode

2021 ◽  
Author(s):  
yong yang ◽  
yufeng wang ◽  
Yujie Gui ◽  
Fuhui Shao ◽  
Yulei Li ◽  
...  
Keyword(s):  
Density Distribution ◽  
Electric Current ◽  
Current Density ◽  
Feeding Rate ◽  
Electrochemical Machining ◽  
Current Density Distribution ◽  
Electric Current Density ◽  
Tool Electrode ◽  
Shaped Tube ◽  
Tubular Electrode

Abstract The coaxial laser has been introduced to shaped tube electrochemical machining (STEM), referred to as Laser-STEM, to enhance the materials removal rate and precision. To address the issue of central residual formation during the Laser-STEM process, which limited the machining stability and feeding rate, the retracted hybrid tubular electrode was applied. The formation mechanisms and effects of the W-shaped central residual were analyzed. Simulation and experiments were conducted to study the impact of the retracted length of the tubular electrode. Simulation results showed that a retracted length of 1-1.5 mm of the inner low-refractive layer could improve the electric current density distribution homogeneity to remove the W-shaped central residual in the machining area. The electric current density distribution homogeneity in the machining zone has been decreased by 38% by utilizing the hybrid tubular electrode with a retracted length of 2.0 mm. With a proper retracted length, the laser coupling efficiency exceeded 74.5%. Hence, the retracted hybrid tubular electrode could act as both the tool electrode and optical waveguide in the Laser-STEM process. Experimental results proved that the machining efficiency and precision of Laser-STEM could be enhanced by utilizing the retracted hybrid tubular electrode. With the retracted length deg rising from 0 mm to 1.5 mm, the maximum feeding speed increased by 373%, and the machining precision was improved by 42.2%. The maximum feeding rate of 4.1 mm/min has been achieved using the retracted hybrid tubular electrode in the Laser-STEM process, which has been improved by 105%, compared with the available maximum feeding rate of the tubular electrode in the STEM process. Finally, the small holes with a diameter of 1.4 mm and an aspect ratio of 15 have been processed by Laser-STEM with the retracted hybrid tubular electrode.

A Research of Shaft Modal Simulation Method Based on the Preloaded Angular Contact Ball Bearing

2013 ◽  
Vol 389 ◽  
pp. 364-370
Author(s):  
Bei Li ◽  
Jian Bin Zhang ◽  
Lu Sha Jiang
Keyword(s):  
Simulation Analysis ◽  
Simulation Method ◽  
Numerical Control ◽  
Angular Contact Ball Bearing ◽  
Tightening Force ◽  
Shaft System ◽  
Element Simulation ◽  
Rolling Element ◽  
Bearing Stiffness ◽  
Main Spindle

In order to analysis modal characteristic of bearing with pre-tightening force on main spindle of numerical control lathe, this paper proposes a model of spindle modality analysis. This model is used to simulate the preloaded bearing shaft system modal, and the simulation results are verified by modal experiment. This paper takes 7005c as the research object to establish the equivalent-spring model based on the Hertz theory considering the pre-tightening force, whose focus is dealing with the contact between bearings rolling element and raceway. Then the model will be used to get the bearing stiffness for finite element simulation analysis. The shafting modal with preloaded bearing test platform is structured to get the shaft system modal parameters, which is compared with and verified the simulation analysis.

Videooptical Surface Shape and Integrity Estimation in Robots Machining

2013 ◽  
Vol 332 ◽  
pp. 270-275 ◽  
Author(s):  
Tadeusz Mikolajczyk
Keyword(s):  
Surface Roughness ◽  
Industrial Robot ◽  
Surface Shape ◽  
Engineering System ◽  
Machined Surface ◽  
Reflectivity Method ◽  
Machining System ◽  
Grinding Tool ◽  
Smart Machining ◽  
Usb Camera

Paper shows system to surface shape and quality control in machining using industrial robot. To surface control videooptical methods were used. Surface shape was controlled using the special reverse engineering system. To surface roughness measure machined surface reflectivity method was used. Used own constructions non contact system was equipped with red laser light and USB camera. Wrist of robot was equipped with grinding tool. In paper shows some algorithms of presented processes. Shown too examples of experiments results in surface roughness measure in start end of grinding process. First trials of presented system shows possibility to build smart machining system for finishing of surface with unknown shape.

scholarly journals Adjustment of Wire Vibrations in Order to Improve Geometric Accuracy and Surface Roughness at WEDM

2021 ◽  
Vol 11 (11) ◽  
pp. 4734
Author(s):  
Ľuboslav Straka ◽  
Ivan Čorný
Keyword(s):  
Surface Roughness ◽  
Economic Efficiency ◽  
Acoustic Emissions ◽  
Tool Electrode ◽  
Geometric Accuracy ◽  
Dynamic Adjustment ◽  
Machined Surface ◽  
Minimal Impact ◽  
The Wire ◽  
Wedm Process

Although WEDM is one of the most precise finishing technologies, deviations from the required geometric shapes and surface roughness occur in the production of parts with rotary surfaces. Even though these shortcomings have only a minimal impact on planar cuts, the production of circular profiles is a different problem. One of the factors causing this poor quality is the vibration of the wire electrode. With appropriate vibration adjustment, it would be possible to achieve significant improvements of the eroded area quality, both in terms of geometric accuracy and in terms of surface roughness. This would significantly increase quality, enabling WEDM technology to compete with other technologies in terms of economic efficiency. Therefore, the proposed solution aims to provide a partial adjustment to the wire tool electrode vibrations, based on their sensing by the means of acoustic emissions or a laser beam, with subsequent dynamic adjustment of the actual technological parameter values. This way, the given solution will increase the production accuracy of circular holes, increase productivity, and ultimately provide an overall increase in the economic efficiency of the WEDM process. The article also presents the scheme of a control algorithm for monitoring and subsequent adjustments of the vibrations of the wire tool electrode during the electroerosion process in order to minimize geometric deviations of circularity, cylindricity and roughness of the machined surface.

ACHIEVING REALISTIC TOW FIBER VOLUME FRACTIONS IN TEXTILE COMPOSITE MODELS BY INDUCING FIBER ENTANGLEMENT

2021 ◽  
Author(s):  
GEORGE BARLOW ◽  
MATHEW SCHEY ◽  
SCOTT STAPLETON
Keyword(s):  
Process Simulation ◽  
Manufacturing Process ◽  
Fiber Bundle ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Simulation Method ◽  
Textile Composite ◽  
Compression Pressure ◽  
Fiber Volume ◽  
Composite Models

Modeling composites can be an effective way to understand how a part will perform without requiring the destruction of costly specimens. By combining artificial fiber entanglement with manufacturing process simulation, a method was developed to create fiber bundle models using entanglement to control the fiber volume fraction. This fiber entanglement generation uses three parameters, probability of swapping (p_(r_S )), swapping radius standard deviation (r_(σ_S )), and the swapping plane spacing (l_S), to control the amount of entanglement within the fiber bundle. A parametric study was conducted and found that the more entanglement within a fiber bundle, the more compression mold pressure required to compact the fiber bundle to the same fiber volume fraction as that required for a less entangled bundle. This artificial fiber entanglement and manufacturing process simulation method for creating fiber bundles shows the potential to be able to create bundles with controlled final volume fraction using a desired mold compression pressure.

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