Cathode design and experimental study on the rotate-print electrochemical machining of revolving parts

Zhu, Zengwei; Wang, Dengyong; Bao, Jun; Wang, Ningfeng; Zhu, Daiyin

doi:10.1007/s00170-015-7172-5

Cited by 51 publications

(8 citation statements)

References 12 publications

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“…Preferential dissolution of M (Ni, Cr) occurred and released M + ions into solution. The following anodic and cathodic reactions may be expressed as equations (1) and (2), respectively. The reactions for the passivation film (M-oxides) formation on the surface and the final productions can be expressed as equations (3) and 4:…”

Section: Electrochemical Dissolution Mechanismmentioning

confidence: 99%

“…Electrochemical machining (ECM) is an advanced technology for shaping difficult-to-machine materials. It employs the dissolution of anodic metals and thereby bypasses the limitations of the alloy's mechanical properties [1], [2]. Compared to conventional machining techniques, ECM offers several advantages, such as high metal removal rate, reduced tool wear, lower residual stress, and excellent ability to cast complex shapes [3]- [5].…”

Section: Introductionmentioning

confidence: 99%

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Electrochemical Dissolution Behavior of Nickel-Based Hastelloy X Superalloy at Low Current Densities

Yin

Zhang

et al. 2020

IEEE Access

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Electrochemical machining (ECM) is a proven processing technique for fabricating difficultto-cut nickel-based superalloys with complex shapes using the principle of anodic dissolution. However, the metallic surface is susceptible to stray corrosion under conditions of low current density, which increases the difficulty of using ECM on nickel-based superalloy such as Hastelloy X (HX). In this study the electrochemical dissolution behavior of wrought HX at low current density was systematically analyzed. The results revealed that M 23 C 6 carbides were irregularly distributed on the grain boundaries. The polarization curves and open-circuit potential measurements showed that an appropriate temperature (35 • C) and concentration (10 wt.%) aided in the formation of efficient and stable dissolution in NaNO 3 solution. The findings also revealed that selective corrosion occurred preferentially on the grain boundary or near the M 23 C 6 precipitations after passivation film polarization. After careful investigation of the different-stage dissolution microstructures and the solid black block-shape products, M 23 C 6 precipitation was found to play a key role in the dissolution of HX alloy at low current density. A qualitative model was established to demonstrate the electrochemical dissolution behavior of wrought HX alloy in NaNO 3 solution. This model offers a new insight into the suppression of stray corrosion of Ni-based superalloys in aerospace applications.

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Section: Electrochemical Dissolution Mechanismmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Electrochemical Dissolution Behavior of Nickel-Based Hastelloy X Superalloy at Low Current Densities

Yin

Zhang

et al. 2020

IEEE Access

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“…As a special machining method, electrolytic machining has become the ideal ma chining method for parts in the aerospace industry and has been widely used in the machining of magazine bosses because it does not generate cutting stress, has no contact with the machined surface, is not limited by the material strength and hardness, and has 5-10 times higher efficiency than mechanical cutting [2]. For the electrolytic processing technology of magazine tabs, electrolytic processing using multiple profiling block electrodes is the mainstream process method [3]; Zhu et al [4][5] used cathode-to-anode rolling (equal angular velocity rotating in opposite directions) to obtain the profile of the rotating body by back -copy electrolytic processing, and proposed the spin-print electrolytic processing technology. Beijing Institute of Aeronautical Manufacturing proposed the rotary scanning electrolytic processing method based on the photographic electrolytic processing technology [6].…”

Section: Introductionmentioning

confidence: 99%

Multi-field Coupling Analysis of Electrolytic Machining of Magazine Mounts Based on COMSOL

Wang

Fan

Zhang

et al. 2023

J. Phys.: Conf. Ser.

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In electrolytic processing, the flow field of the electrolyte, the applied voltage, and the magnetic effect of the current itself have a significant effect on the stability, efficiency, and surface quality of the process. In this paper, the effects of different inlet pressures on the flow rate and different treatment voltages on the current density and magnetic induction strength are investigated by coupling several fields, such as flow, electric and magnetic fields, using COMSOL software. The simulation results show that the flow rate increases with the increase of inlet pressure, and the flow rate increases by 1 m/s for every 0.1 MPa. The current density increases with the increase of processing voltage, but its uniformity decreases, and the magnetic effect of the current itself also influences the magnitude of the current density

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“…Due to high material hardness and complex inner spiral structure, traditional processing method cannot meet the actual needs. While electrochemical machining has the advantages of not limited by material mechanical properties, no cutting stress and high machining e ciency, it has become an irreplaceable processing method for such parts [4][5][6][7][8][9][10]. As the core component of horizontal NC ECM machine tool, the rationality of its structure and performance has a great impact on the reliable processing of the machine tool.…”

Section: Introductionmentioning

confidence: 99%

Analysis and Test of Conductive Shaft of Large Horizontal NC ECM Machine Tool

Tang

Zheng

Shi

et al. 2021

Preprint

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In order to solve the problems of serious heating and easy ablation of conductive shaft in electrochemical machining of special-shaped deep hole with large aspect ratio, the two schemes of single side copper bar and symmetrical copper bar of conductive shaft were studied by ANSYS software. And the conductive shaft scheme based on symmetrical copper bar scheme was determined. The thermoelectric coupling model of the conductive shaft was established to analyze the distribution law of temperature field and thermal deformation of conductive shaft under different working conditions. Through the machining test of special-shaped inner spiral deep hole parts with large aspect ratio, the results show that under the conditions of working current of 15 000 A, feed rate of 5 mm/min and continuous machining for 14 hours, the forming accuracy of the workpiece is ±0.15 mm and the surface roughness is better than Ra0.8 µm. The performance of the conductive shaft is stable and meets the actual processing requirements. The heat dissipation performance of the conductive shaft can be optimized by providing air flow on the upper surface and side at the same time.

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Cathode design and experimental study on the rotate-print electrochemical machining of revolving parts

Cited by 51 publications

References 12 publications

Electrochemical Dissolution Behavior of Nickel-Based Hastelloy X Superalloy at Low Current Densities

Electrochemical Dissolution Behavior of Nickel-Based Hastelloy X Superalloy at Low Current Densities

Multi-field Coupling Analysis of Electrolytic Machining of Magazine Mounts Based on COMSOL

Analysis and Test of Conductive Shaft of Large Horizontal NC ECM Machine Tool

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