Investigation on the electrochemical machining of micro groove using masked porous cathode

Simulation Analysis and Process Evaluation of Cooling Hole Forming Precision in Mask Assisted Electrochemical Machining Based on GH4169

“…In this paper, through studying the principle of electrochemical corrosion, combining with classical electrochemical theory, the simulation model of mask electrochemical machining is established, and the distribution of electric field in the process of mask and unmasked electrochemical machining is analyzed. Through simulation experiments, the influence of different mask diameters and heights on the size and morphology of cooling holes in electrochemical machining is studied, and the mask electrochemical machining process has no damage and can be reused, which improves the machining efficiency [ 45 , 46 ]. Based on the current density of workpiece surface obtained by multi-physical field coupling simulation model, with the help of any Lagrange-Eulerian formula, the mathematical model of anode boundary movement with respect to current density is established, and the formation law of the size and shape of cooling holes in electrochemical machining under different machining voltages and electrolyte inlet flow rates is analyzed.…”

Jet Electrochemical Micromachining of Micro-Grooves with Conductive-Masked Porous Cathode

“…The main experiment parameters are listed in Table 2. In our previous research, we have found that increasing the reciprocating motion number (increasing the moving speed of nozzle) could reduce the machining roughness in high machining voltage (high current density), but it has little influence on the machining roughness in low voltage (low current density), because there was less electrolytic product [29]. According to the simulation result in Figure 3, it is found that with a conductive mask, the electric field intensity on the workpiece is quite lower than that with an insulated mask, which means a low current density on workpiece during machining.…”

“…For the electrochemical machining of micro-grooves, the key to improve the machining quality is to enhance the mass transfer effect in the machining region and reduce overcut to heighten the localization. In previous research [29], we have proposed a method of electrochemical machining of micro-grooves with masked porous cathode, the influence of different flow modes on the machining process was investigated, and a jet flow mode was optimized at last, which could improve the machining efficiency and dimensional uniformity. However, the undercut of micro groove is unavoidable due to the isotropy of material when the traditional insulated mask was used, which reduced the machining localization.…”

Fabrication of Massive Metal Microstructures by Rotating Through-mask Electrochemical Transferring Technology

“…[18] 。该法把预先制备好的掩 膜机械地(无粘结)压贴工件或工具表面上，再进行 掩膜电解加工。因为该法的掩膜可从工件或工具上 多次无损分离，可反复使用，所以它能极大缩减操 纵步骤，提高工艺适用性，大幅降低工艺成本。 可复用掩膜紧密可靠地压贴在工件上，是上 述活动掩膜电解加工发挥正常制造能力的前提， 但这却是极富挑战性的难题，尤其当被加工表面 是曲面时。对此，曲宁松教授 [19] 采用仿形性好的 聚二甲基硅氧烷(PDMS)材料来制备活动掩膜，以 期提高加工精度。本文作者团队则从优选和开发 新的掩膜压贴介质和方式着手，先后提出极间柔 性多孔物填充型掩膜电解加工 [20] 和泡沫阴极掩膜 电解加工 [21] ，较好地解决了曲面工件上活动掩膜 的紧密可靠压贴难题。陈晓磊等 [22][23][24] 提出了射流 掩膜电解加工并通过采用惰性导电阴极、复合阴 极等措施进一步改善该技术的加工精度。最近， DIVYANSH 等 [25] 报道了一种改进型多孔阴极活…”