Computer Simulation of Low Frequency Vibration in Electrochemical Machining

Abstract

This research studies how particles transport between low frequency vibrating electrodes during electrochemical machining (ECM). The ANSYS Fluent software was used to study the particle speed while the Star CCM+ software was utilized to study particle interactions during vibration-assisted ECM process. A series of simulations were conducted to calculate the particle average flushing speed. Collided particles either gained momentum or deflected their trajectories to accelerate in the flow of electrolyte. Simulation results showed that the highest average flushing speed of 0.4 m/s was obtained at 40 Hz vibration frequency and 10 µm vibration amplitude. Such higher flushing speed of particles improved machining depth (material removal rate) and produced a sharper machined profile. Experiment results confirmed that the maximum machining depth and minimum taper angle were obtained when vibrating the anodic workpiece at 40 Hz and 10 µm amplitude. Machining depth and ECM material removal rate had a positive correlation with the average flushing speed. A sharper ECM’ed profile was achieved since the taper angle was favorably reduced at high average flushing speed.

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

“…Different traditional and modern techniques are nominated to enhance surface quality of the workpiece according to cost, time, workpiece material, and surface complexities demands. In recent decades, the vibration of a tool or workpiece is known as an efficient assistant technique in conventional [1][2][3][4][5][6][7][8][9][10][11][12][13] and non-conventional [14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31] machining processes. Vibratory and ultrasonic machining are two main non-conventional polishing processes, which are based on vibration phenomenon.…”