Some aspects of the electrochemical machining process supported by electrode ultrasonic vibrations optimization

Ruszaj, Adam; Zybura, Maria; Żurek, R.; Skrabalak, Grzegorz

doi:10.1243/095440503322617135

Cited by 52 publications

(25 citation statements)

References 6 publications

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“…The total pressure (P) in the frontal gap for the vibrating tool in the ECM process can be expressed as P = P 1 + P 2 + P 3 (16) where (P 1 + P 2 ) equals the inlet pressure in the machining cell, thus…”

Section: Effect Of Tool Vibration On the Electrolyte Pressurementioning

confidence: 99%

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Modelling the performance of ECM assisted by low frequency vibrations

Hewidy

Ebeid

El-Taweel

et al. 2007

Journal of Materials Processing Technology

100

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Section: Effect Of Tool Vibration On the Electrolyte Pressurementioning

confidence: 99%

“…Ruszaj et al [16] proved that the electrode ultrasonic vibrations help to decrease the surface roughness parameter (R a ) in comparison to the classical ECM process. Morozov [17] studied the ECM performance using the pulse voltage applied in synchronization with the tool vibration.…”

Section: Introductionmentioning

confidence: 99%

Modelling the performance of ECM assisted by low frequency vibrations

Hewidy

Ebeid

El-Taweel

et al. 2007

Journal of Materials Processing Technology

100

View full text Add to dashboard Cite

“…Process of the microbubbles collapse in area adjacent to electrode gives possibility for increasing the intensification of mass and electric charge transportation. As was presented in [5,6,8,9,13], ultrasonic vibrations have the significant influence on the kinetics of electrode processes conditions and increases the rate of electrochemical dissolution.…”

Section: Introductionmentioning

confidence: 99%

Research on ultrasonically assisted electrochemical machining process

Skoczypiec

2010

Int J Adv Manuf Technol

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Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials and to shape free-form surfaces. In ECM, material is removed by electrochemical dissolution process, so part is machined without inducing residual stress and without tool wear. To improve technological factors in electrochemical machining, introduction of electrode tool ultrasonic vibration is justifiable. This method is called as ultrasonically assisted electrochemical machining (USAECM). In the first part of the paper, the analysis of electrolyte flow through the gap during USAECM has been presented. Based on computational fluid dynamic methods, multiphase, turbulent and unsteady electrolyte flow between anode and cathode (under assumption that cavitation phenomenon occurs) has been analysed. Discussion of the obtained solutions is the base to define optimal conditions of electrolyte flow in case of USAECM process. The second part of the paper is connected with experimental investigations of USAECM process. Classic experimental verification of obtained results in case of machining is extremely difficult, but influence of the ultrasonic vibration can be observed indirectly by changes in technological factors (in comparison to machining without ultrasonic intensification), whereas results of numerical simulation give possibility to understand reason and direction of technological factors changes. Investigations proved that ultrasonic vibrations change conditions of electrochemical dissolution S. Skoczypiec (B) Institute of Production Engineering, Cracow University of Technology, Al. Jana Pawla II 37, 31-864, Krakow, Poland e-mail: skoczypiec@m6.mech.pk.edu.pl and for optimal amplitude of vibration gives possibility to decrease the electrode polarisation.

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“…Pulsed electric fields [1][2][3], ultrasonic velocity [4,5], and magnetic fields [6] are three common assistances used in an anodic dissolution electrochemical cell [7]. In anodic dissolution-based manufacturing processes such as electrochemical machining (ECM) and electrochemical finishing/polishing (ECF/P), these assistances have been reported to result in higher material removal rate (MRR), improved surface finish, increased accuracy, and higher electrical efficiency [7].…”

Section: Introductionmentioning

confidence: 99%

Controlled Phase Interactions Between Pulsed Electric Fields, Ultrasonic Motion, and Magnetic Fields in an Anodic Dissolution Cell

Bradley

Samuel

2018

Journal of Manufacturing Science and Engineering

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This paper presents the design of a novel testbed that effectively combines pulsed electric field waveforms, ultrasonic velocity, and magnetic field waveforms in an anodic dissolution electrochemical machining (ECM) cell. The testbed consists of a custom three-dimensional (3D)-printed flow cell that is integrated with (i) a bipolar-pulsed ECM circuit, (ii) an ultrasonic transducer, and (iii) a custom-built high-frequency electromagnet. The driving voltages of the ultrasonic transducer and electromagnet are calibrated to achieve a timed workpiece velocity and magnetic field, respectively, in the machining area. The ECM studies conducted using this testbed reveal that phase-controlled waveform interactions between the three assistances affect both the material removal rate (MRR) and surface roughness (Ra) performance metrics. The triad-assisted ECM case involving phase-specific combinations of all three high-frequency (15.625 kHz) assistance waveforms is found to be capable of achieving a 52% increase in MRR while also simultaneously yielding a 78% improvement in the Ra value over the baseline pulsed-ECM case. This result is encouraging because assisted ECM processes reported in the literature typically improve only one of these performance metrics at the expense of the other. In general, the findings reported in this paper are expected to enable the realization of multifield assisted ECM testbeds using phase-specific input waveforms that change on-the-fly to yield preferential combinations of MRR and surface finish.

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Some aspects of the electrochemical machining process supported by electrode ultrasonic vibrations optimization

Cited by 52 publications

References 6 publications

Modelling the performance of ECM assisted by low frequency vibrations

Modelling the performance of ECM assisted by low frequency vibrations

Research on ultrasonically assisted electrochemical machining process

Controlled Phase Interactions Between Pulsed Electric Fields, Ultrasonic Motion, and Magnetic Fields in an Anodic Dissolution Cell

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