Drilling investigations on Inconel alloy 625 material of material removal rate using micro electrochemical machining

Udhayakumar, Gobikrishnan; Suresh, P.; Kumaravel, P.

doi:10.1016/j.matpr.2020.07.173

Cited by 8 publications

(2 citation statements)

References 6 publications

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“…4 Electrochemical machining (ECM) is a process wherein the metal workpiece as the anode is anodized in the electrolyte to remove materials and realize the forming process. [5][6][7][8] ECM affords high processing efficiency and can process difficult-to-machine materials. Consequently, it is widely used in the manufacturing of integral structural parts.…”

Section: Introductionmentioning

confidence: 99%

Research on depth control of machining trace in electrochemical trepanning

Zhu

Zhang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrochemical trepanning (ECTr) is a highly effective and economic manufacturing technology for machining difficult-to-cut metal materials that are often used in aeroengine components. Integral structural components such as blisks, diffusers, etc. are composed of hubs and blades. In continuous ECTr, machining trace stems from on the hub between adjacent blades. The depth of machining trace significantly influences the surface integrity of the integrated components, even causes the scrapping of the workpiece. In order to solve the problem of machining trace in ECTr, a cathode design method based on the relation between cathode profile and electric field distribution is proposed in this study, the edge of the cathode that affects the machining trace is chamfered. A electric field model of ECTr is established and dynamic electric field simulation of ECTr for cathodes with different chamfered edges is performed. The electric field intensity distribution at the cathode edge and the forming profile of the hub are compared. The simulation results show that optimal chamfering parameters can improve the machining trace. Subsequently, a group of cathodes with different chamfered edge is designed, and corresponding ECTr experiments are conducted. The optimal chamfering parameters are determined (α = 5°, b = 2 mm), the depth of the machining trace is reduced from 0.370 mm to 0.122 mm, the surface flatness is significantly improved. Overall, this depth control method of machining trace is verified effectively.

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Section: Introductionmentioning

confidence: 99%

Research on depth control of machining trace in electrochemical trepanning

Zhu

Zhang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The service temperatures of Inconel 625 range from cryogenic to 982°C, 2 and Inconel 625 has excellent weldability and brazeability. 3 The properties of Inconel 625 make it an excellent choice for the blades of aeroengines to improve performance. 4 Under the stiffening effect of molybdenum and niobium on its nickel-chromium matrix, Inconel 625 is extremely strong, thereby making it difficult to process with conventional milling.…”

Section: Introductionmentioning

confidence: 99%

Electrochemical trepanning of blades made of Inconel 625

Lei

Zhu

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the aerospace field, difficult-to-machine materials are used widely to improve engine performance. As a nickel-based material that performs well in all aspects, Inconel 625 is used for the blisks of aircraft engines, and electrochemical trepanning (ECTr) is used widely to fabricate such blisks because of its unique advantages regarding ruled surface parts. In this study, to investigate the performance of Inconel 625 in ECTr, measurements were made of the electrochemical characteristics firstly, specifically the anodic polarization curve and the actual volumetric electrochemical equivalent curve. Then, via dynamic electric-field simulations, the processes for forming Inconel 625 blades using ECTr were examined under direct voltage (DV) and pulsed voltage. The contours and current density distributions of formed blades at different times were obtained under different duty cycles. With decreasing duty cycle, the forming accuracy improved gradually and the stray current was reduced. To verify the simulation results, ECTr experiments with Inconel 625 were performed under different voltage conditions. With DV and 90% and 80% duty cycle, the taper angles of the machined blades were 7.784°, 6.278°, and 5.191°, respectively, and the surface roughness ( Ra) values were 0.95, 0.81, and 0.72 μm, respectively. With DV, there were obvious flow marks and gullies on the microscopic surface. With decreasing duty cycle, stray corrosion was reduced effectively and the state of the flow field was improved. Overall, the simulation results were verified effectively.

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FE simulation, analytical prediction, and experimentation of cutting force in longitudinal vibration-assisted milling (LVAM) during Ti-6Al-4 V cutting

Kurniawan

Han

et al. 2023

Int J Adv Manuf Technol

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Drilling investigations on Inconel alloy 625 material of material removal rate using micro electrochemical machining

Cited by 8 publications

References 6 publications

Research on depth control of machining trace in electrochemical trepanning

Research on depth control of machining trace in electrochemical trepanning

Electrochemical trepanning of blades made of Inconel 625

FE simulation, analytical prediction, and experimentation of cutting force in longitudinal vibration-assisted milling (LVAM) during Ti-6Al-4 V cutting

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