Research on the Process Simulation of NC-ECM with Ball-End Tool-Electrode

Abstract

In order to solve the difficult problem in analyzing the shaping law of numerical control electrochemical machining (NC-ECM) with ball-end cathode, the process simulation based on the finite element method (FEM) is used in this paper. First, the two-dimensional analysis model of the electric field in NC-ECM with ball-end tool-electrode built by use of ANSYS software was solved, and the current density distribution and the machined surface shape on the workpiece were obtained. Then, the experiments based on the simulation parameters were carried out, and the cutting depth values were measured. Finally, the accuracy of the simulation was verified by the comparison between the calculated values and the actual values. The experiments showed that the simulation method meets the accuracy of the engineering calculations in NC-ECM.

Modeling on Volumetric Material Removal for Fabrication of Complex Shapes by EC Milling of Ti6Al4V

“…The formation of these characteristics like radius of curvature, side angle and obtained length are mostly dependent on two most important process parameters of EC milling e.g milling layer thickness and tool feed rate. 12 So, in this paper an attempt has been made to develop a mathematical relation between the major process parameters like milling layer thickness and feed rate on the volumetric material removal in EC milling. In the relation, volumetric material removal is obtained in terms of side angle, radius of curvature and the obtained length of the groove.…”