Influence of inner-spraying rotating tool during electrochemical milling of Nimonic-263 alloy

Mishra, K.; Sarkar, B. R.; Bhattacharyya, B.

doi:10.1080/10426914.2019.1594277

“…Pilot experiments have been conducted at different tool feed rates and MLD to produce grooves on the workpiece and range of the taken parameters has been chosen carefully. It has been stated in the authors' former research work that EC milling of Nimonic-263 alloy using NaCl (1M) and NaNO 3 (1M) mixed electrolyte generated excellent surface finish in the order of 0.06-0.08 mm; 15 thus, for this study, same electrolyte has been utilized. Fixed process parameters have been kept constant as listed in Table 2 and variable process parameters have been listed in Table 3.…”

Section: Experimental Planningmentioning

confidence: 99%

“…It is also worth to mention that EC milling without any tool rotation produces some unwanted impressions of the flow lines at the machined surface which deteriorates the quality of machined surface. 15 For this reason for further study, that is, improvement of accuracy of the machined profile with different featured tools, 8 mm/min feed rate and MLD of 0.3 mm with rotation of the tool has been kept constant.…”

Section: Impact Of Feed Rate and Mld With Tool Rotation On Wocmentioning

confidence: 99%

Influence of different featured tools on machining accuracy in electrochemical milling

Mishra

¹

,

Sarkar

²

,

Bhattacharyya

³

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

Self Cite

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Drawbacks of electrochemical machining can be conquered to a large extent with the introduction of electrochemical milling technique. In this method, a simple shaped tool follows a predetermined tool path and material gets removed atom-by-atom from anode workpiece by electrochemical reactions through layer-by-layer approach. Keeping in mind the rising trend of electrochemical milling technique, this research work focuses to investigate the impact of major process parameters of electrochemical milling, for example, feed rate and milling layer depth on foremost responses like material removal rate and width overcut during electrochemical milling of Nimonic-263 alloy. In this research work, three different types of featured tools have been utilized and for each tool, ANSYS simulation has been carried out for analysing their impact on machining accuracy. Furthermore, these obtained simulated results have been confirmed by experimentation. Finally, an attempt has been made to produce more accurate ‘L’-shaped features on Nimonic-263 alloy with the aid of tool rotation and inner-spraying featured tools. This study confirms that mixed electrolyte, that is, NaCl(1M) + NaNO3(1M), tool rotation with internal flushing, number of outlets and the structure of the end face of the tool generate excellent machining accuracy with super finished surface with Ra value in the order of 0.07–0.08 µm during electrochemical milling of Nimonic-263 alloy.

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“…In terms of the tool movement, Mitchell-Smith et al 14 improved the electrochemical jet machining performance of Inconel 718 alloy by adjusting the jet angle through nozzle rotation. Mishra et al 15 used the tool rotation to improve the flow field distribution of Nimonic-263 alloy electrochemical milling, and eliminated the flow disorder on the bottom surface. Zhao et al 16 used the tool vibration to eliminate the sudden change of flow field in the frontal gap of special-shaped holes electrochemical machining (ECM), and promoted the uniform dissolution of stainless steel materials.…”

Section: Introductionmentioning

confidence: 99%

Flow field characteristics and experimental research on inner-jet electrochemical face grinding of SUS420J2 stainless steel

Feng

¹

,

He

²

,

Wu

³

et al. 2022

Sci Rep

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Electrochemical grinding (ECG) is processed by the combination of dissolution and grinding. It is very suitable for the processing of difficult-to-cut stainless steel, but its processing performance is restricted by the matching effect of dissolution and grinding. In this work, the processing of the torus surfaces of the stainless steel shaver cap was taken as the research object. A flow field model including the through-hole structure and the rotation of the grinding head was proposed to optimize the flow field distribution and promote the uniform dissolution of materials. The flow field simulation results showed that the rotational flow formed by the high-speed rotation prolonged the electrolyte flow path and was not conducive to the discharge of electrolytic products, and the reasonable selection of the diameter and distribution of the through-hole could reduce the velocity difference. The effects of rotational speed, feed rate, and inlet pressure on the flatness and surface roughness of the torus surfaces were experimentally investigated, and a better matching effect of dissolution and grinding was obtained. Moreover, the experimental results showed that the inner-jet ECG had a good prospect in the batch processing of high-hardness stainless steel parts.

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“…In terms of the tool movement, Mitchell-Smith et al [14] improved the electrochemical jet machining performance of Inconel 718 alloy by adjusting the jet angle through nozzle rotation. Mishra et al [15] used the tool rotation to improve the ow eld distribution of Nimonic-263 alloy electrochemical milling, and eliminated the ow disorder on the bottom surface. Zhao et al [16] used the tool vibration to eliminate the sudden change of ow eld in the frontal gap of specialshaped holes electrochemical machining (ECM), and promoted the uniform dissolution of stainless steel materials.…”

Section: Introductionmentioning

confidence: 99%

Flow Field Characteristics and Experimental Research on Inner-Jet Electrochemical Face Grinding of SUS420J2 Stainless Steel

Wang

¹

,

He

²

,

Wu

³

et al. 2021

Preprint

0

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Electrochemical grinding (ECG) is processed by the combination of dissolution and grinding. It is very suitable for the processing of difficult-to-cut stainless steel, but its processing performance is restricted by the matching effect of dissolution and grinding. In this work, the processing of the torus surfaces of the stainless steel shaver cap was taken as the research object. A flow field model including the through-hole structure and the rotation of the grinding head was proposed to optimize the flow field distribution and promote the uniform dissolution of materials. The flow field simulation results showed that the rotational flow formed by the high-speed rotation prolonged the electrolyte flow path and was not conducive to the discharge of electrolytic products, and the reasonable selection of the diameter and distribution of the through-hole could reduce the velocity difference. The effects of rotational speed, feed rate, and inlet pressure on the flatness and surface roughness of the torus surfaces were experimentally investigated, and a better matching effect of dissolution and grinding was obtained. Moreover, the experimental results showed that the inner-jet ECG had a good prospect in the batch processing of high-hardness stainless steel parts.

show abstract

Influence of inner-spraying rotating tool during electrochemical milling of Nimonic-263 alloy

Cited by 20 publications

References 10 publications

Influence of different featured tools on machining accuracy in electrochemical milling

Influence of different featured tools on machining accuracy in electrochemical milling

Flow field characteristics and experimental research on inner-jet electrochemical face grinding of SUS420J2 stainless steel

Flow Field Characteristics and Experimental Research on Inner-Jet Electrochemical Face Grinding of SUS420J2 Stainless Steel

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