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 Flushing Enhancement with Vibration and Pulsed Current in Electrochemical Machining

2017 ◽  
Vol 2 (4) ◽  
pp. 67-85 ◽  
Author(s):  
Zhujian Feng ◽  
Jesus Manuel Orona-Hinojos ◽  
Pedro Perez Villanueva ◽  
Paul Lomeli ◽  
Wayne NP Hung
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Three Dimensional ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Steel Plates ◽  
Electrode Gap ◽  
Taper Angle ◽  
Low Frequency Vibration

This research aims to understand flushing of by-products in electrochemical machining (ECM) by modeling and experimentally verifying mechanism of particle transport in inter-electrode gap under low frequency vibration. A series of hole were drilled on steel plates to evaluate the effect of vibration on material removal rate and hole quality. Infinite focus optical technique was used to capture and analyze the three-dimensional images of ECM'ed features. Experimental results showed that maximum machining depth and minimum taper angle can be achieved when vibrating the workpiece at 40 Hz and 10 µm amplitude. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at this vibration frequency and amplitude. Machining depth and material removal rate has a positive correlation with the average flushing speed. Sharper ECM’ed profile is obtained since the taper angle is favorably reduced at high average flushing speed.

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

scholarly journals Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

2021 ◽  
Author(s):  
Dragan Rodic ◽  
Marin Gostimirovic ◽  
Milenko Sekulic ◽  
Borislav Savkovic ◽  
Branko Strbac
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Positive Effects ◽  
Assisting Electrode

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

EXPERIMENTAL INVESTIGATIONS INTO THE INFLUENCING PARAMETERS OF ELECTROCHEMICAL MACHINING OF AISI 202

2008 ◽  
Vol 07 (02) ◽  
pp. 337-343 ◽  
Author(s):  
T. SEKAR ◽  
R. MARAPPAN
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
High Energy ◽  
Experimental Investigations ◽  
Metal Removal Rate ◽  
Hard Materials ◽  
Influencing Parameters ◽  
Traditional Process

Electrochemical machining (ECM) is a non-traditional process used mainly to cut hard or difficult to cut metals, where the application of a more traditional process is not convenient. Those difficult to cut metals demand high energy to form chips, which can result in thermal effects due to the high temperatures inherent to the process in the chip–tool interface. In traditional processes, the heat generated during the cut is dissipated to the tool, chip, workpiece and environment, affecting the surface integrity of the workpiece, mainly for those hard materials. In this work, experimental investigations have been made on the various influencing parameters involved in the Metal removal rate (MRR) and Surface roughness using ECM on AISI 202 steel. The major intervening parameters are studied and the relationship between the parameters has been determined to achieve maximum metal removal rate and minimum surface roughness by using NaNO 3-Aqua solution.

Numerical Investigation on the Effect of Abrasive Property for Abrasive Flow Machining

2014 ◽  
Vol 574 ◽  
pp. 406-410
Author(s):  
Li Feng Yang ◽  
Chun Yan Dong ◽  
Wei Na Liu
Keyword(s):  
Material Removal ◽  
Volume Fraction ◽  
Metal Removal ◽  
Particle Volume Fraction ◽  
Three Dimensional ◽  
Three Dimensional Model ◽  
Particle Volume ◽  
Micro Holes ◽  
Micro Hole ◽  
Abrasive Property

Numerical investigations of the abrasive influence on material removal efficiency of the micro-hole for AFM process is conducted in this paper. A three-dimensional model is constructed for this process. The abrasive with various particles volume fraction and different micro-holes with various diameters are selected in this study. The simulation results show that the lower particle volume fraction may be in favour of the metal removal uniformity, but the processing time will be too long if too low fraction is selected.

Dynamic Analysis of the Ultrasonic Machining Process

1996 ◽  
Vol 118 (3) ◽  
pp. 376-381 ◽  
Author(s):  
Z. Y. Wang ◽  
K. P. Rajurkar
Keyword(s):  
Dynamic Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Equations Of Motion ◽  
Three Dimensional ◽  
Dynamic Contact ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Factors Affecting ◽  
Good Agreement

This paper presents a dynamic analysis of the ultrasonic machining process based on impact mechanics. Equations representing the dynamic contact force and stresses caused by the impinging of abrasive grits on the work, are obtained by solving the three-dimensional equations of motion. The factors affecting the material removal rate have been studied. It is found that the theoretical estimates obtained from the dynamic model are in good agreement with the experimental results.

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.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

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