Electrochemical machining analysis on grid cathode composed of square cells

During the electrochemical machining (ECM), the cathodes designed by the existing methods are mainly unitary cathodes, which can be only used to produce the workpieces with the same shapes. However, there are few researches on designing cathodes for machining the different workpieces with the different surfaces. This paper presents the grid cathode composed of the square cells to produce the workpieces with different shapes. Three types of the square cells, 2.5 mm′2.5 mm, 3 mm′3 mm, and 4 mm′4 mm, are utilized to construct the plane, the slant, and the blade cathode. The material of the cathode and the anode is CrNi 18 Ti 9 , and the ingredient of electrolyte is 15% NaCl and 15% NaNO 3 . The machining equilibrium machining current and time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors on the workpiece surface are measured and analyzed, and the error reasons are traced and discussed to obtain the better surface quality of the workpiece. The experiment and analysis results show that the grid cathode can be used to manufacture the workpieces with complex shapes in certain range of the error. The workpiece quality improves with the size of the square cell being reduced, and if the square element is small enough, the workpiece quality is almost equal to the one machined by the unitary cathode. The proposed research realizes a single cathode machining the different workpieces with the different surfaces.     

Experimental study on the confined flow over a circular cylinder with a splitter plate

An experimental study was carried out to investigate the effect of a splitter plate on wake flows downstream of a circular cylinder symmetrically placed in a confined channel. A particle image velocimetry (PIV) measurement was applied to visualize the flow structure and analyze changes in the vortex shedding process. The control elements of the splitter plate length, L/D (D is the cylinder diameter) was varied from 0 to 1.5 and Reynolds number, Re_D was considered at 2400 and 3000. The experimental results showed that the splitter plate had an influence on stabilization of wake turbulences in a confined channel. For shorter splitter plate length of L/D=0.5 and 0.75 cases, flow structures were significantly modified and the vortex shedding frequency decreased as compared with bare cylinder cases. For longer splitter plate length of L/D=1, 1.25 and 1.5 cases, the generation of a secondary vortex was observed based on the snapshot proper orthogonal decomposition (snapshot POD) analysis. In addition, turbulent characteristics corresponding to turbulent kinetic energy (TKE) and Reynolds shear stress correlations took the lowest values and the dominant vortex shedding frequency disappeared. There was an optimal value of the splitter plate length at L/D=1 on suppression of velocity fluctuations. Moreover, the stabilizing effect of a splitter plate was more obvious at Reynolds number of Re_D=3000 than that at Re_D=2400.     

脉冲电流电解加工试验研究

介绍脉冲电流电解加工原理,通过正交试验方法进行脉冲电流电解加工试验,对所得到的试验结果采用线性回归 分析方法进行分析,得出脉冲电流电解加工工艺参数对表面粗糙度的影响关系。     

膛线电解加工阴极新型结构设计

电解加工技术应用到炮管膛线加工中相比传统机械拉削是一种创新,并且已成功应用于中小口径的炮管膛线加工.但采用阴极工作齿固定式阴极加工大口径、变缠角的深槽膛线则会导致膛线加宽,产生"塌壁".拟设计新型的随动式电解加工阴极总体结构,讲述各部件的功能,达到阴极工作齿随着炮管膛线缠角的变化而变化,通过数控程序可实现任意缠角的膛线加工,彻底解决膛线"塌壁"问题,极大的提高了膛线的精度,将对我国的大口径炮管深膛线加工产生深远影响.     

Experimental investigation on monitoring interelectrode gap of ECM with six-axis force sensor

To realize on-line monitoring interelectrode gap, six-axis force sensor was embedded into main spindle of machine tool to measure force signals on cathode exerted by electrolyte. The force signals, three forces, and three moments in X, Y, Z directions, respectively, are considered as research parameters. On one hand, the forces exerted on the tool cathode by electrode are measured with six-axis force sensor as electrolyte flow system is activated and electrode is deactivated. On the other hand, the forces are tested when electrolyte flow system and electrode are both activated. Then, the relation between six force components and interelectrode gap are analyzed. Machining experiments using three types of tool, e.g., plane tool, slant tool, and blade tool, have been carried out to deduct experiential equations between six force components and gap according to least squares method. Furthermore, the experimental data with blade tool are put into experiential equation with slant tool to examine validity of measuring gap in ECM. The relation of parameters in equations is analyzed and a conclusion is drawn: in the range of 15% error, machining experiential equation with slant tool can be used to on-line measure the interelectrode gap in ECM.     

Low energy-consumption plasma electrolytic oxidation based on grid cathode

Plasma electrolytic oxidation (PEO) has attracted widespread attention owing to the simplicity of operation and the excellent properties of the formed coating. However, wider applications of PEO have been limited due to the high power consumption. This work describes the design and performance of a novel technique named shorter distance PEO (SD-PEO), which is intended for lowering the energy consumption. The key feature of the method is the application of grid cathode to eliminate the gaseous envelope effect and to block of the exchange of charge carries during SD-PEO process. Compared to PEO carried out at a normal electrode distance, e.g., 50 mm, both the voltage drop and the joule heat consumed in the electrolyte at a shorter distance, e.g., of 5 mm (SD-PEO) are relatively small. Consequently, the energy consumption rendered by the novel SD-PEO method may decrease by more than 25%. Our results reveal that SD-PEO is a low energy-consumption microarc oxidation technique with more potential in industry applications.     

Optimal design of the sheet cathode using W-shaped electrolyte flow mode in ECM

Electrochemical machining (ECM) is an important non-conventional manufacture technology for machining workpieces with complex and thin structures. In this study, ECM is used to machine the blisk. Because the channel between two blades is narrow, the cathode must use the thin-sheet structure. In the ECM process, the cathode will bear electrolyte pressure which can cause deformation. The cathode deformation has negative influence on the machining quality and process stability. To minimize the deformation, the optimization treatment of the cathode thickness is carried out and a new electrolyte flow mode, W-shaped flow mode, is adopted to weaken the pressure. The corresponding computer simulation is applied, and the results show that the cathode deformation decreases by 17.6% and 28% by taking the above-mentioned two measures. It indicates that the new thin-sheet cathode presented in this paper is useful and the new flow mode is effective in ECM. Furthermore, the experiments are conducted using the optimal thickness electrode and W-shaped flow mode to verify the machining effects. Then the corresponding experiment is carried out, and the result shows that the optimal treatments to reduce the cathode deformation have remarkable effects.     

Experimental investigation of heat transfer enhancement in a circular duct with circumferential fins and circular disks

The characteristics of heat transfer and pressure drop for fully developed turbulent flow in a tube with circumferential fins and circular disks were experimentally studied. The various spacing and sizes of circumferential fins and circular disks were selected as design parameters, while the effects of these parameters on heat transfer enhancement and pressure drop were investigated. In order to quantify the effect of heat transfer enhancement and the increase of pressure drop due to the fins and disks in a tube, the Nusselt numbers and the friction factors for various configurations and operating conditions were compared to those for a corresponding smooth tube. The results showed that the heat transfer rate was significantly enhanced by increasing the height of circumferential fins and decreasing the pitch of circumferential fins. On the other hand, the influence of the disk size and the fin-disk spacing were not significant. Based on the experimental results, a correlation for estimating the Nusselt number was suggested.     

小尺度圆形通道内流动换热特性试验研究

对圆形细通道流动与换热特性进行了试验测量,着重考察了通道几何参数(直径、长度)对其流阻系数和换热系数的影响规律,试验中雷诺数Re范围为500～5000.研究结果表明:通道直径越小,通道内流体的流阻系数越大,换热系数越大;通道长度越长,通道内流体的流阻系数越小.这将为圆形细通道的应用提供参考.     

基于电解液非线性特性的叶片电解加工阴极设计

叶片是航空发动机的关键零件,以某型航空发动机转子叶片为研究对象,针对叶片电解加工阴极设计这一工程问题,着重考察了采用非线性电解液进行加工时,电解液的非线性特性对阴极设计的影响.本文首先建立了模型叶片的三维实体造型,在此基础上探讨了电解液的非线性特性对电解加工过程和阴极设计产生影响的机理,通过半实验法与数据库技术相结合的方式有效的将这种非线性特性集成到阴极设计方法中.     

圆形出液口悬浮阴极平面电化学加工间隙建模及实验研究

提出利用极间电解液液膜支撑阴极悬浮形成加工间隙,通过调节流量和电流实现极间间隙的调节和控制的新方法。以圆形出液口悬浮阴极平面电化学加工为例,基于流体力学和电极过程动力学理论建立加工间隙的数学模型,得到间隙与流量、压差及电流之间的关系。利用Fluent软件对间隙模型流场特性进行分析,得到间隙中电解液的压力场和速度场的分布情况,进而得到进出口压差和出口流速;实验获得不同流量、电流条件下的加工间隙。理论模型计算结果和实验数据结果相近,变化规律基本一致。     

A numerical study on mixed convection in a lid-driven cavity with a circular cylinder

A two-dimensional numerical simulation is carried out in this study to investigate mixed convection in a lid-driven cavity with an isothermal circular cylinder. The simulation is conducted at three Reynolds numbers of Re = 100, 500, and 1000 under a fixed Grashof number of Gr = 10⁵. The top wall of the cavity moves to the right at a constant velocity and is kept at a low temperature of T _c , whereas the stationary bottom wall is kept at a constant high temperature of T _h . The immersed-boundary method, which is based on the finite volume method, is adopted for the boundary of the circular cylinder that is present in the square cavity. The present study aims to investigate the effects of circular cylinder on fluid flow and heat transfer in a cavity at different locations. The fluid flow and heat transfer characteristics in the cavity strongly depend on the position of the circular cylinder as well as on the relative magnitude of the forced convection and the natural convection caused by the movement in the top wall of the cavity and the heating at the hot bottom wall, respectively.     

Micro ECM with ultrasonic vibrations using a semi-cylindrical tool

In recent years, there has been a growing demand for micro holes. However, electrochemical machining has rarely been employed in drilling these holes because of problems with electrolyte diffusion. In this research, a semi-cylindrical tool was used as a tool electrode to increase the flow space of the electrolyte, and electrolyte diffusion was improved via the application of ultrasonic vibrations. Micro holes with a specified diameter of 76 μm were drilled on a 304 stainless steel plate of 300μm thickness. The proposed technique reduced both the machining time and the machining gap.     

钛合金深窄槽可控振动辅助电解加工试验研究

为提高TB6钛合金深窄槽电解加工精度,基于电场仿真分析方法,研究了不同加工方式深窄槽侧壁电流密度和电化学溶解速度分布规律,并采用工艺试验方法对持续进给、振动进给、脉冲与振动耦合3种加工方式进行对比研究。试验结果表明：振动频率和持续进给速度固定时,提高振幅能够显著降低槽宽标准差,提高深窄槽加工一致性;持续进给速度相同时,脉冲与振动耦合的平均槽宽和槽宽标准差均较小,加工精度更高。采用脉冲与振动耦合加工方式,深窄槽入口处平均槽宽为2.62 mm,沿深度方向平均槽宽为2.73 mm,入口处槽宽标准差为0.05 mm,沿深度方向槽宽标准差为0.03 mm。     

Computational study of flow in a curved pipe with circular cross section

Laminar imcompressible flows in a circular sectioned pipe were investigated by seeking numerical solutions to the Navier-Stokes equations. Three semi-circular pipes of radius ratios 0.05, 0.143 and 0.148 were studied. These calculations covered the Dean number ranging from 183 to 3847. In the range of low and medium Dean numbers, a steady-state solution was obtained; when the Dean number was high, a three-dimensional separation and the associated secondary flow were clearly observed far downstream near the outlet. Extensive flow visualizations were made to depict the computed results.     

Experimental and numerical study of heat transfer downstream of an axisymmetric abrupt expansion and in a cavity of a circular tube

This research is an experimental and numerical investigation of heat transfer and fluid flow characteristics in separated, recirculated and reattached regions created by an axisymmetric abrupt expansion and by an abrupt expansion followed by an abrupt contraction (called a “cavity”) in a circular tube at a uniform wall temperature. The flow just upstream of the expansion was unheated and proved to be fully-developed at the entrance to the heated cavity region. Local heat transfer coefficients were measured using a balance-type isothermal heat flux gage. Measurements were made at a small-to-large tube diameter ratio of d/D = 0.4 and downstream Reynolds numbers ranging from Re_D = 4,300 to 44,500. Generally, the maximum Nusselt numbers downstream of an axisymmetric abrupt expansion at a uniform wall temperature occur between 9 and 12 step heights from the expansion step. Numerical simulation has been carried out by a two-equation turbulence model and its results such as mean velocity profiles and local Nusselt numbers are in good agreement with experimental results.     

Research on ECM process of micro holes with internal features

Micro holes with internal features are widely used as spray holes and cooling holes nowadays, which are usually required to be with high aspect ratio and shape accuracy, as well as good surface quality. An electrochemical machining (ECM) process is presented to machine these micro holes with diameter <200 μm. A quantitative relation between micro-hole diameter and machining parameters including voltage, duty ratio and feedrate is obtained through orthogonal experiments. According to the designed shape of internal features, change rules of machining parameters for varied diameters in different depth are obtained, and then micro holes with internal features are shaped precisely. Taking reverse tapered hole as an example, ECM experiments by varying parameters of voltage, duty ratio and feedrate (called varying voltage machining, varying duty ratio machining and varying feedrate machining, respectively) are carried out. Micro holes with inlet diameter of 178 μm and taper angle of 1.05° are shaped on a 1.0 mm-thick workpiece of 18CrNi8. The deviation of inlet is <3 μm and the taper-angle error is <0.1° in varying voltage machining. The corresponding dimensional accuracy of taper angle is improved by 51% than that of varying duty ratio machining under the same efficiency. The machining efficiency of varying voltage machining is increased by 36% compared to the efficiency in varying feedrate machining. In addition, the micro holes with complex features of funnel shape and bamboo shape are machined.     

电解加工过程多物理场耦合仿真及试验研究

针对电解加工过程中复杂、难以预测的问题,建立小孔内扩孔电解加工过程多物理场耦合的数学模型,利用COMSOLMultiphisics软件进行仿真分析,得到加工间隙内的流速分布、电流密度分布和温度分布,并分析了不同加工时间和电压对温度分布的影响。选择合适的工艺参数进行试验,得到了小孔内壁轮廓曲线的实测值,并与耦合多物理场仿真的理论值、未耦合多物理场(仅电场)仿真的理论值进行对比。结果表明,耦合多物理场仿真的理论值与实测值更接近,误差更小,可以准确地模拟实际电解加工过程。     

Behaviour of a squeeze film between curved circular plates with a concentric circular pocket

The behaviour of the squeeze film formed between two circular plates when a curved upper plate approaches a flat lower plate which has a concentric circular pocket was studied. The introduction of the pocket reduces the load capacity of the bearing.