Cathode optimization and multi-physics simulation of pulse electrochemical machining for small inner-walled ring grooves

Zhang, Changfu; Ai, Haihong; Yan, Zhenghu; Jiang, Xinguang; Cheng, Peiyong; Hu, Yanwei; Tian, Hao

doi:10.1007/s00170-019-04634-w

Cited by 13 publications

(5 citation statements)

References 14 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The effective distance between the tool and the wall of the trough was about 500 nm. The machining accuracy was about four times higher than that in reference [4]. The well-defined shape and nanometerscale precision of the micro spiral beam demonstrates the detection technique of the ion concentration during pulsed electrochemical micromachining.…”

Section: Monitor Ion Concentration Change Based On Double Sensor Smentioning

confidence: 77%

See 1 more Smart Citation

Dual-Sensing System for Monitoring Ion Concentration Change in Electrochemical Micro Machining

Zhao

2020

IEEE Access

View full text Add to dashboard Cite

Currently, no reliable electrolyte concentration monitoring method exists for ultra-short pulsed electrochemical micromachining. A dual-sensing system for electrolyte concentration monitoring is proposed in this work. An inductance element is added into the classical pulsed electrochemical micromachining circuit system. For it, a modified circuit equation is proposed by which the coupled electronic and ion circuit is analyzed, and two modes of the coupled circuit are found. The asynchronous mode is used to monitor the concentration changes of the ions in electromechanical micromachining, and a novel method of electrolyte concentration monitoring is obtained. Combining this method with the shortcircuit frequency monitoring method, an electrolyte concentration monitoring method based on the dualsensing monitoring system is proposed, and corresponding monitoring software is produced. The software is used in actual microstructure processing experiments, obtaining nanometer-scale machining accuracy. INDEX TERMS dual sensing system, monitoring ion concentration, electrochemistry, micro machining.

show abstract

Section: Monitor Ion Concentration Change Based On Double Sensor Smentioning

confidence: 77%

“…For ECM technology, various simulation methods have been proposed. A multi-physics simulation was carried out, and cathode optimization was completed to improve the accuracy of the inner-walled ring grooves [4]. A multiphysics model was proposed to model the temperature evolution in the pulsed electrochemical machining process [5].…”

Section: Introductionmentioning

confidence: 99%

Dual-Sensing System for Monitoring Ion Concentration Change in Electrochemical Micro Machining

Zhao

2020

IEEE Access

View full text Add to dashboard Cite

show abstract

“…Koyano machined micro-textured pattern by means of the ultra-short pulse electrochemical machining technique 14 . Zhang optimized the tool cathode structure and machining parameters in the pulsed electrochemical machining technology, and improved the machining quality of the small ring groove on the inner wall of the nozzle 15 .…”

Section: Introductionmentioning

confidence: 99%

Electrochemical micro-machining based on double feedback circuits

Wang

Zhao

2023

Sci Rep

View full text Add to dashboard Cite

Pulsed electrochemical micromachining accuracy predominantly depends on pulse duration. To obtain high accuracy, an expensive power source with ultra-short pulse duration is needed. An electrochemical micromachining method based on double feedback circuits is proposed in this work to achieve this aim. A positive feedback circuit plus a negative feedback circuit is used in the circuit of the pulsed electrochemical micromachining. Thus, the gains of the feedback circuits can control the pulse duration of the machining system. Experiments show that the machining resolution can be improved notably by an increase in the feedback gains. Using the method, one micro double cure beam is produced, and its accuracy gets to nanometer level under the condition of using an ordinary pulse duration power source.

show abstract

“…Manikandan et al [5] used the gray correlation analysis method to establish a mathematical model of the influence of the tube electrode electrochemical machining feed rate, electrolyte flow rate, and electrolyte concentration on the material removal rate and machining gap, and obtained an optimized parameter combination. Zhang et al [6] used the k-ε turbulence model to simulate the flow field of electrochemical machining, designed the tool cathode structure, and analysed the design of the cathode and the workpiece under different processing conditions through multiphysics simulation. The electric field characteristics verify that the designed cathode can meet the processing requirements.…”

Section: Introductionmentioning

confidence: 99%

Effects of Machining Parameters on Electrochemical Multi-Field Coupling

CHEN

Zhang

et al. 2022

mech

View full text Add to dashboard Cite

Electrochemical machining involves three couplings between electric field, flow field and thermal field. The precipitation of hydrogen on the surface of the cathode will affect the entire electrochemical machining process and the final machining quality of the workpiece. Finite element software is used to analyze the effects of different voltages, electrolyte inlet pressure and interelectrode gap on current density, hydrogen volume fraction, conductivity and temperature distribution in this article. The research results show that the increase of processing voltage will increase the current density, hydrogen volume fraction and temperature, and decrease the conductivity of the solution. As the pressure of the electrolyte increases, the current density and conductivity increase, but the hydrogen volume fraction and temperature decrease. The current density, hydrogen volume fraction and temperature decrease, and the conductivity increases when the gap between electrodes increases. At the inlet, the current density and conductivity are relatively large, and gradually decrease along the electrolyte flow direction, while the hydrogen volume fraction and temperature are the smallest at the inlet, and gradually accumulate along the electrolyte flow direction, and reach the maximum at the outlet. Through multi-physics coupling simulation, the current density, temperature, conductivity and bubble distribution in electrochemical machining can be predicted, which can provide a theoretical basis for actual electrochemical machining process parameter selection.

show abstract

Cathode optimization and multi-physics simulation of pulse electrochemical machining for small inner-walled ring grooves

Cited by 13 publications

References 14 publications

Dual-Sensing System for Monitoring Ion Concentration Change in Electrochemical Micro Machining

Dual-Sensing System for Monitoring Ion Concentration Change in Electrochemical Micro Machining

Electrochemical micro-machining based on double feedback circuits

Effects of Machining Parameters on Electrochemical Multi-Field Coupling

Contact Info

Product

Resources

About