Modeling and Simulation of the Electrochemical Machining (ECM) Material Removal Process for the Manufacture of Aero Engine Components

Klocke, Fritz; Zeis, Markus; Harst, Simon; Klink, Andreas; Veselovac, D.; Baumgartner, María T.

doi:10.1016/j.procir.2013.06.100

Cited by 107 publications

(41 citation statements)

References 6 publications

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“…To extend the present result to application of highperformance manufacturing with various methods delivering different external loads of mechanical, thermal, chemical nature or a combination of them [25][26][27], the surface integrity change induced by stress field, stain field, temperature field, etc. should be considered accordingly with respect to the specific external loads.…”

Section: Discussionmentioning

confidence: 92%

Inverse surface integrity problem in ultrasonic impact-treated AISI 304 stainless steel components

Wang

Zhu

Lei

et al. 2016

Int J Adv Manuf Technol

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The inverse problem for surface integrity is still not solved in practice during high-performance component manufacturing, i.e., it is not possible selecting an appropriate process as well as process parameters in advance according to the given surface integrity required for the high performance. The desired surface integrity is usually created by trial and error based on an iterative approach due to lack of quantitative correlations between the loads of a process and the surface integrity variations during manufacturing. The inverse surface integrity problem is studied for manufacturing AISI 304 stainless steel components by employing an ultrasonic impact treatment (UIT) to achieve an enhanced fatigue performance. The correlations are explored between the process loads of mechanical impact, corresponding material loading within the treated component and surface integrity change in the surface layer due to surface modification. Based on experimental and numerical studies, such correlations of UIT process are identified primarily as the quantitative correlation between external mechanical load and material loading of strain and stress, and that between material loading and changes in surface integrity parameters such as residual stress and microhardness due to surface modification. It is demonstrated that a knowledge-based solution of the inverse surface integrity problem is possibly achieved by establishing the correlations to derive process parameters from a given surface integrity for manufacturing of high-performance components.

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Section: Discussionmentioning

confidence: 92%

Inverse surface integrity problem in ultrasonic impact-treated AISI 304 stainless steel components

Wang

Zhu

Lei

et al. 2016

Int J Adv Manuf Technol

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“…In paper [3], the authors propose a model that was developed when solving the related problems above, whereby some parameters were either assumed to be constant, or the range within which they could change would be pre-specified based on other parameters and preliminary experimental research of samples, machined correspondingly. The authors modeled the shaping process for the specified tool electrode profile as well as copying the TE profile using a reference blade.…”

Section: Methodsmentioning

confidence: 99%

Computer-aided design system for GTE blades electrochemical machining technology

2017

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Abstract. The paper presents the results of computer-aided design of GTE blade electrochemical machining. Developed a method to use ANSYS to calculate electric fields in the electrochemical cello under ECM. We created an electronic reference base and refined the dissolution model applicably to PECM. In addition, we developed a method for profiling tool electrodes DC ECM and PECM. The calculation module uses parametric relationships with Siemens NX by means of Excel files to produce output TE designs as a 3D computer models. The subsystem developed contains an ECM shaping model, has a modular structure, and is implemented as a wizard.

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“…Lots of efforts have been devoted to blisk ECM. A multi-physical approach is presented for modeling the ECM material removal process by coupling all relevant conservation equations [6]. Flow models such as Π-shaped flow mode and dynamic additional electrolyte flow are developed to raise quality of electrolyte flow field [7,8].…”

Section: Introductionmentioning

confidence: 99%

Development Of A Cathode Designing Method To Avoid Electrodes’ Interference During Blisk Electrochemical Machining

Zhang¹,

Xu²,

Su³

et al. 2016

Kms

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Electrochemical machining plays a prominent role in blisk (bladed integrated disk) construction process. Since blisk channel is narrow and twisted, interference between electrodes may happen during electrochemical machining. Therefore, this paper develops a cathode designing method to avoid interference. Firstly, according to theory of electrochemical machining, machined channel is predicted by calculation. Second, with this channel, interference analysis is carried out and a cathode is designed. Finally, the cathode is employed in experiment and no interference appears.

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Modeling and Simulation of the Electrochemical Machining (ECM) Material Removal Process for the Manufacture of Aero Engine Components

Cited by 107 publications

References 6 publications

Inverse surface integrity problem in ultrasonic impact-treated AISI 304 stainless steel components

Inverse surface integrity problem in ultrasonic impact-treated AISI 304 stainless steel components

Computer-aided design system for GTE blades electrochemical machining technology

Development Of A Cathode Designing Method To Avoid Electrodes’ Interference During Blisk Electrochemical Machining

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