Precision improvements in ECM via tool insert development by 3D printing

Sneddon, Scott; Silva, A.K.M. De; Gomez-Gallegos, Ares; Jayasinghe, Prabodha

doi:10.1016/j.procir.2022.09.200

Cited by 3 publications

(3 citation statements)

References 6 publications

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“…The cross-section image (see Figure 3 (c)) highlights the shape change required. A 3D printed ECM closed-cell design was selected, this setup has been shown to allow more control over the electrolyte flow and measure key parameters such as flow rate, pressure and temperature within the cell [17]. The initial development of the machining cell required a trial-and-error phase to obtain the desired rod shape.…”

Section: Industrial Case Studymentioning

confidence: 99%

Simulation of electrolyte behaviour of industrial electrochemical machining

Moro,

Sneddon,

Gomez-Gallegos

et al. 2023

Preprint

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Development of simulation models for electrochemical machining (ECM) is a widely researched challenge to avoid the traditional trial and error process, with potential resulting advantages in terms of time, cost, and sustainability. To this objective, it is crucial to utilise software that can accurately simulate the complex multiphysics aspects of ECM without being too computationally expensive and with a fast set up. This paper investigates an alternative finite element software to model ECM for industrial production. The specific features of this software make it attractive for industrial applications, and in this work, it is validated as suitable to model the electrolyte characteristics of flow rate and pressure. The model developed is the basis for determining local changes to electrolyte conductivity, current density, and efficiency as a function of gap spacing optimisation in order to achieve the desired geometry with dimensional accuracy and assure process repeatability for industrial production. Simulation results are in agreement with the experimental ECM carried out as part of this work.

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Section: Industrial Case Studymentioning

confidence: 99%

Simulation of electrolyte behaviour of industrial electrochemical machining

Moro,

Sneddon,

Gomez-Gallegos

et al. 2023

Preprint

Self Cite

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“…In order to produce a precise shape in a workpiece, it is always necessary to develop a customized and often complex removal fixture [10,11]. Undesired stray current phenomena cause design iterations, ensuring high dimensional accuracy [12,13].…”

Section: Introductionmentioning

confidence: 99%

“…To limit the propagation of this field, PECM typically uses narrow working gaps between the two electrodes (5 µm to 50 µm), which crucially localize the ablation [14]. In addition, the exact positioning of the electrical insulation in the fixture system plays an essential role [11,15].…”

Section: Introductionmentioning

confidence: 99%

Simulation-Assisted Tool Design for Pulsed Electrochemical Machining of Magnetic Shape-Memory Alloys

Böttcher,

Schaarschmidt,

Edelmann

et al. 2024

JMMP

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Shape-memory alloys set high demands on the production technologies being used. During cutting, continuous heat input and mechanical stress have an undesirable influence on the shape-memory effect. Pulsed electrochemical machining (PECM), which is based on anodic dissolution, enables force-free machining without thermomechanical influence on the edge-zone properties of the workpiece. Depending on the desired geometry, the development of a customized PECM fixture is necessary. The design of the fixtures is often based on the experiences of the designers and manufacturers, which often results in an estimation of the functionally critical dimensions. For this reason, the study focuses on a methodical approach for evaluating crucial fixture dimensions using knowledge of the specific material dissolution behavior linked with a numerical simulation model. It has been shown that the shape-memory alloy NiMnGa has a non-linear dissolution behavior in sodium nitrate. A reduction of stray currents up to 20% resulting from a lateral gap between the cathode and electrical insulation was demonstrated using numerical simulation. The study shows that a low cathode shaping height has the strongest influence on precise processing. Varying the process parameters allowed for the lateral gap to be adjusted between 0.15 and 0.25 mm.

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