Analysis of Electrolyte Flow in IEG During Electrochemical Grinding of MMC

Gupta, Nisha; Dubey, Avanish Kumar; Rahi, Dhruv Kant

doi:10.1007/978-981-15-3639-7_36

Cited by 4 publications

(3 citation statements)

References 12 publications

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“…The MRR by the erosion process was very small, and it increased with the rotational speed. 3 A mathematical model based on the finite element method was established by Fan et al to study the electrochemical grinding process. The results showed that the electrochemical characteristics could be well predicted for the performance of electrochemical grinding in different electrolytes.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and experimental study on electrochemical milling of cemented carbide

He,

Xu,

Guo

et al. 2023

Advances in Mechanical Engineering

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In response to the difficulties in machining cemented carbide, this paper proposes a new approach to electrochemical milling of cemented carbide. A composite rotating tool cathode for electrochemical milling is designed, and the electric field simulation calculation is conducted for the electrochemical milling process. The electric field results show that as the tool cathode continues to penetrate, the machining area of electrochemical milling continues to increase, and the current density in the machining gap increases. After the tool cathode enters the semicircle, if the processing area of electrochemical milling remains unchanged, the amount of material removed per unit time remains unchanged, and the current density also remains stable. At the same time, orthogonal experiments and process parameter optimization were conducted on the electrochemical milling of cemented carbide side edges. The results showed that the maximum material removal was achieved under the process parameters of processing voltage 14 V, feed speed 10 mm/min, spindle speed 3000 r/min, and duty cycle of 70%. Based on the optimized process parameters of side-edge electrochemical milling, full edge electrochemical milling of experiment was carried out. When the feed rate is 0.3 mm/min, the surface of cemented carbide electrochemical milling is relatively flat and has a roughness of 0.389 μm.

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Section: Introductionmentioning

confidence: 99%

Numerical simulation and experimental study on electrochemical milling of cemented carbide

He,

Xu,

Guo

et al. 2023

Advances in Mechanical Engineering

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“…They found that wheel wear is mostly initiated by the breakdown of abrasive grains during the machining process. Gupta et al 28 showed the effect of flow velocity in inter electrode gap (IEG) on various performance characteristics of ECG through ANSYS software.…”

Section: Introductionmentioning

confidence: 99%

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Rahi

Dubey

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Hybrid metal matrix composites have superior strength to weight ratio as compared with conventional composites or superalloys. This characteristic makes them suitable for different advanced industries such as aerospace, automobile, and biomedical. Mechanical and thermal energy based processes have their own limitations to machine these composites due to superior mechanical properties and melting of reinforcement particles, respectively. Researchers are trying to machine metal matrix composites by the electrochemical process with the aim to achieve better machining quality, but low material removal rate and oxide layer formation on the machined surface has emerged as the main limitation. A hybrid variant of electro-chemical machining (ECM) and conventional grinding has capability to overcome these limitations. Keeping this in view, the experimental set-up of electro-chemical surface grinding (ECSG) has been developed with the aim to compare the machining characteristics of the hard-to-cut hybrid metal matrix composite Al–SiC–Gr with the ECM process. The machining performances have been compared on the basis of material removal rate, surface roughness, and microcrack width in the machined component. The influence of some important input process parameters on these performance characteristics have been analyzed scientifically. Experimental results show that the ECSG process improves the machining performance by reducing or eliminating the oxide layer from the machining zone due to suitable grinding effects. Material removal rate, surface roughness, and microcrack width were improved by 68%, 24%, and 40%, respectively, by using the ECSG process. The formation of the large size oxide layer with high crack width on the machined surface was observed at high voltage, high electrolyte concentration, and at low table speed.

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“…The results showed that the shear stress increased with the rotational speed of the grinding wheel for a xed inter-electrode gap, and the same was found for the shear force. The MRR by the erosion process was very small, and it increased with the rotational speed [3]. A mathematical model based on the nite element method was established by Fan to study the electrochemical grinding process.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Study on Electrolytic Grinding/Milling of Cemented Carbide

Xu²,

Guo³

et al. 2022

Preprint

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Cemented carbide is widely used in industrial production owing to its high hardness, high strength, and excellent wear and corrosion resistance. However, traditional machining is prone to machining defects such as cracking and burn. To address this problem, the cathode of a cemented carbide electrolytic grinding/milling tool was designed in this study. The distribution of the electric field of full-edge electrolytic grinding/milling was numerically simulated, and the variation in the electric field was obtained. A four-factor four-level orthogonal test of the side-edge electrolytic grinding/milling process was carried out, and the process parameters were optimized through range analysis. Based on the obtained results, the influence of feed speed on full-edge electrolytic grinding/milling was investigated. A cemented carbide electrolytic grinding/milling sample was fabricated and measured. The measurement results show that the surface is relatively flat and has a roughness of 0.389 μm. The obtained parameters meet the requirements of cemented carbide finishing.

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Analysis of Electrolyte Flow in IEG During Electrochemical Grinding of MMC

Cited by 4 publications

References 12 publications

Numerical simulation and experimental study on electrochemical milling of cemented carbide

Numerical simulation and experimental study on electrochemical milling of cemented carbide

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Numerical Simulation and Experimental Study on Electrolytic Grinding/Milling of Cemented Carbide

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