Multi-physical field coupling for vibration feed electrochemical machining of diamond-shaped hole in titanium alloy

He, Yuan; Gan, Weimin; Yin, Fengshi; Zhao, Jianshe; Xu, Bo; Yu, Qing; Yang, Lei

doi:10.1007/s00170-019-04701-2

Cited by 12 publications

(5 citation statements)

References 17 publications

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“…The major advantage of non-conventional machining processes is that machining of any hardto-cut metal to high accuracy is possible regardless of the complexity of the shape. These processes can also be used for machining at both large and micro scales, but machining at micro scale may require additional accessory like in the case of wire or vibration assisted ECM [110,111] and jet-ECM [112]. Another non-conventional machining process that differs from the LBM, EDM and ECM is ultrasonic machining (USM) [113].…”

Section: Non-conventional Machiningmentioning

confidence: 99%

“…The authors recommended that insulation coating of microtools used in ECM could help improve the process and prevent the formation of tapered hole. He et al [110] also showed that a diamond shaped hole could be generated on a TC4 titanium alloy using a multi-physical field coupling for generating vibrations assisted electrochemical machining. The vibration facilitated a reciprocating motion of the cathode tool such that insoluble matter was discharged in the surface of the titanium alloy in the processing region.…”

Section: Electrochemical Machiningmentioning

confidence: 99%

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An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

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Section: Non-conventional Machiningmentioning

confidence: 99%

Section: Electrochemical Machiningmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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“…Feng [22] investigated the effects of compound feed and matching of pulse and oscillation (MOPAO) on the mean current density distribution of deep and narrow grooves of TB6 titanium alloy, which significantly improved the machining accuracy. At present, the main research objects of electrochemical machining of hole parts are focused on micro-hole [23], type hole [24], tapered hole [25], etc.…”

Section: Introductionmentioning

confidence: 99%

Study on Electrochemical Machining of Involute Internal Spline of Cr-Co-Mo-Ni High Hardness Gear Steel

Huang

Yao²,

Wang³

et al. 2023

Preprint

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Cr-Co-Mo-Ni high-hardness steel is widely used in critical mechanical transmission components. It has the difficult-to-cut characteristic because of its high hardness and high strength. In the cutting process, the machining cutting force is large, the tool is worn quickly, and the machining accuracy is poorly maintained. In view of the machining problems, this paper carried out a research on the electrochemical machining process of internal spline of high hardness gear steel. Firstly, a two-dimensional geometric model of electrochemical machining electric field simulation is established based on the structural characteristics of the internal spline electrochemical machining fixture. The electric field simulation analysis of internal spline electrochemical machining is carried out based on numerical analysis method. The influence law of electrolyte conductivity, processing voltage and cathode feed speed on electrochemical machining forming is studied. Meanwhile, a three-dimensional model of Electrochemical machining flow field simulation is established, and the flow field simulation analysis of internal spline Electrochemical machining is carried out. The influence law of electrolyte flow direction and electrolyte back pressure on the flow field distribution is explored. The platform of electrochemical machining system is set up. An experimental study on electrochemical machining of involute internal splines is carried out to further optimize the electrochemical machining process parameters. The test results showed that the electrolysis accuracy and efficiency of the 41-tooth involute spline workpiece are optimized when the electrolyte is 8% NaNO3, the back pressure of the electrolyte is 0.2 MPa, the feed speed is 1.8 mm/min, and the processing voltage is 16.0 V. The efficiency and accuracy of this proposed method can meet the actual processing needs. It has important application value for advanced machining technology of high-performance materials.

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“…Mishra Technology studied the cathode structure based on the ow eld simulation model of transverse groove ECM, and concluded that symmetrical and uniform placement of cathode holes can improve the gap ow eld homogeneity [17]. In order to improve the forming accuracy, scholars have established a multiphysical eld coupling model of uid-electric-temperature structure to explore the variation law of electrolyte velocity and bubble distribution in the gap ow eld [18][19][20][21][22]. In the aspect of inner spiral parts with large aspect ratio process test, Mahdavinejad designed and optimized the cathode of small caliber gun barrel ri ing and carried out experimental research [23].…”

Section: Introductionmentioning

confidence: 99%

Optimization and experimental study on cathode structure of electrochemical machining Titanium alloy inner helix

Tang,

Ma,

Xue

et al. 2023

Preprint

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In order to solve the problem of gap flow field divergence and poor forming accuracy in the electrochemical machining (ECM) titanium alloy inner helix. The pull reverse flow and pull downstream cathode physical models as well as the simulation models of machining gap flow field are established respectively in this paper. Different inclination angles of the liquid supply hole effected on the pull downstream cathode rotational flow field uniformity was explored. The results showed that the gap flow field distribution of the pull downstream cathode is better than pull reverse flow cathode, and the distribution of the rotational flow field formed when the inclination angle of the liquid supply hole achieves 40° is relatively uniform. Under the condition of voltage 12 V, cathode feed speed 15 mm/min, composite electrolyte 3%NaCl+10%NaNO3+6%NaClO3, temperature 30 °C, and electrolyte inlet pressure 2 MPa, the 800 mm length of titanium alloy inner helix sample was machined stably and reliably by the pull downstream cathode structure, which surface roughness is Ra0.8μm.

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Multi-physical field coupling for vibration feed electrochemical machining of diamond-shaped hole in titanium alloy

Cited by 12 publications

References 17 publications

An overview of conventional and non-conventional techniques for machining of titanium alloys

An overview of conventional and non-conventional techniques for machining of titanium alloys

Study on Electrochemical Machining of Involute Internal Spline of Cr-Co-Mo-Ni High Hardness Gear Steel

Optimization and experimental study on cathode structure of electrochemical machining Titanium alloy inner helix

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