Fluid structure interaction of thin graphite electrodes during flushing movements in sinking electrical discharge machining

Klocke, Fritz; Zeis, Markus; Heidemanns, L.

doi:10.1016/j.cirpj.2017.09.003

Cited by 10 publications

(3 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…[52], or even three-phase flow including gas bubbles. Various authors analyzed the flushing conditions during ED processes using Reynolds-averaged Navier-Stokes (RANS) approaches within commercial software, such as CFX [7,38,48,53,54] or Fluent [37,40,[55][56][57][58][59][60][61], both by ANSYS, INC., Canonsburg, PA, USA, but also COMSOL Multiphysics by COMSOL, INC., Burlington, VT, USA [35,[62][63][64][65], or STAR-CCM+ by SIEMENS INDUSTRY SOFTWARE INC., Plano, TX, USA [66]. The degrees of complexity of the RANS modeling approaches are equally crucial but quite different in the existing works.…”

Section: State Of the Artmentioning

confidence: 99%

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

View full text Add to dashboard Cite

The electro-discharge (ED) drilling of precision boreholes in difficult-to-machine materials, particularly with respect to the cost-effectiveness of the overall process, is still a challenge. Flushing is one key factor for the precise machining of boreholes, especially with high aspect ratios. Therefore, the influence of internal and external flushing geometries for six types of brass tool electrodes with a diameter of 3 mm with and without a helical groove was analyzed experimentally and numerically. Using this helical external flushing channel, drilling experiments in X170CrVMo18-3-1 (Elmax Superclean) with an aspect ratio of five revealed a material removal rate (MRR) that was increased by 112% compared with a rod electrode, increased by 28% for a single-channel tool electrode and decreased by 8% for a multi-channel tool electrode. Signal analyses complemented these findings and highlighted correlations between classified discharge event types and the experimental target parameters. Amongst others, it was verified that the arcing frequency ratio drove the electrode wear rate and the beneficial frequency ratio correlated with the MRR and the surface roughness Ra. Sophisticated 3D computational fluid dynamics (CFD) models of the liquid phase were introduced and evaluated in great detail to demonstrate the validity and further elucidate the effect of the external flushing channel on the evacuation capability of debris and gas bubbles. The presented methods and models were found to be suitable for obtaining in-depth knowledge about the flushing conditions in the ED drilling working gap.

show abstract

Section: State Of the Artmentioning

confidence: 99%

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Uhlmann,

Polte,

Yabroudi

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

“…(2021) studied the interaction of multiphase turbulent flow with a thin-walled workpiece for precision ECM. Klocke et al . (2018) modelled the use of thin electrodes with high aspect ratio in sinking electric discharge machining using FSI technique.…”

Section: Introductionmentioning

confidence: 99%

“…As an example of these solutions, Rommes et al (2021) studied the interaction of multiphase turbulent flow with a thin-walled workpiece for precision ECM. Klocke et al (2018) modelled the use of thin electrodes with high aspect ratio in sinking electric discharge machining using FSI technique. Gilmanov et al (2015) studied the large deformation problems of thin bodies with turbulent flow using Dirichlet-Neumann partitioning technique.…”

Section: Introductionmentioning

confidence: 99%

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Aslan,

Kanber,

Demirtas

et al. 2024

MMMS

View full text Add to dashboard Cite

PurposeThe purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.Design/methodology/approachAn experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.FindingsLarge deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.Originality/valueWhen the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

show abstract

Funkenerosives Abtragen (EDM)

Bergs,

Klocke

2024

Fertigungsverfahren 3

View full text Add to dashboard Cite

Fluid structure interaction of thin graphite electrodes during flushing movements in sinking electrical discharge machining

Cited by 10 publications

References 21 publications

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Helical Electrodes for Electro-Discharge Drilling: Experimental and CFD-Based Analysis of the Influence of Internal and External Flushing Geometries on the Process Characteristics

Investigation of electrolyte pressure effect on blisk blades during electrochemical machining

Funkenerosives Abtragen (EDM)

Contact Info

Product

Resources

About