Modeling and experimental investigation of gas film in micro-electrochemical discharge machining process |
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| Affiliation: | 1. Associated Engineering Research Center of Mechanics & Mechatronic Equipment, Shandong University, Weihai City 264209, PR China;2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education of China, School of Mechanical Engineering, Shandong University, Jinan City 250061, PR China;1. Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India;2. Production and Industrial Engineering Department, PEC University of Technology, Chandigarh 160012, India |
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| Abstract: | Electrochemical discharge machining (ECDM) is a promising machining technology that effectively machines non-conducting and brittle materials, featuring good material removal rate, flexibility, and accuracy of machining. ECDM makes use of the electrochemical discharge phenomenon to trigger the discharging by the gas film surrounding the tool electrode. As the fundamental of electrochemical discharging, gas film is essential to the machining quality and efficiency. However, modeling of gas film in electrochemical reaction is not well established. This paper presents analytical modeling of the gas film, involving bubble growth and departure on electrode, gas film evolution, and electrolysis characteristics. Experiments were carried out to compare models to the actual discharging phenomenon. High speed camera imaging demonstrated the formation of a gas film on the tool electrode. The range of thickness of gas film found in experiments indicated good consistency with the range of film thickness estimated from analytical models. Experiments on critical voltages and currents further revealed the characteristics of the gas film in electrochemical reaction. |
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| Keywords: | Electrochemical discharge machining (ECDM) Glass micro-machining Gas film Bubble evolution Process modeling |
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