Chengwei Shen, Ji Wang, Ping Zhou, Ying Yan, Dongming Guo
{"title":"Multi-factor coupling analysis of electric field distribution in electrochemical machining with electrolyte suction tool","authors":"Chengwei Shen, Ji Wang, Ping Zhou, Ying Yan, Dongming Guo","doi":"10.1016/j.precisioneng.2024.07.011","DOIUrl":null,"url":null,"abstract":"<div><p>Electrochemical machining (ECM) technology holds significant potential for applications in high accuracy engineering and manufacturing. To confine the electrolyte region during ECM and mitigate the effects of reaction products and heat generation, an electrolyte suction tool has been proposed. However, the complex electric field distribution on the anode surface during the application of pulse voltage, limits the further utilization of ECM with suction tool. A multi-physics simulation model is established to calculate the region of electrolyte confinement by the suction tool, current density distribution within the electrolyte region, and material removal. The model considers the combined effects of polarization and double layer, and all key parameters are calibrated through classical electrochemical testing experiments rather than fitted based on the predicted results. This study elucidates the transient response of current density on the anode surface during the application of pulse voltage. The simulation accuracy is validated by comparing experimental and simulated current waveforms, as well as material removal profiles under different pulse parameters and electrode shapes. This research is of great significance for improving surface precision and controllability of complex structures in ECM with suction tool, promoting its further application in the field of precision machining.</p></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"89 ","pages":"Pages 504-516"},"PeriodicalIF":3.5000,"publicationDate":"2024-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0141635924001636","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
Electrochemical machining (ECM) technology holds significant potential for applications in high accuracy engineering and manufacturing. To confine the electrolyte region during ECM and mitigate the effects of reaction products and heat generation, an electrolyte suction tool has been proposed. However, the complex electric field distribution on the anode surface during the application of pulse voltage, limits the further utilization of ECM with suction tool. A multi-physics simulation model is established to calculate the region of electrolyte confinement by the suction tool, current density distribution within the electrolyte region, and material removal. The model considers the combined effects of polarization and double layer, and all key parameters are calibrated through classical electrochemical testing experiments rather than fitted based on the predicted results. This study elucidates the transient response of current density on the anode surface during the application of pulse voltage. The simulation accuracy is validated by comparing experimental and simulated current waveforms, as well as material removal profiles under different pulse parameters and electrode shapes. This research is of great significance for improving surface precision and controllability of complex structures in ECM with suction tool, promoting its further application in the field of precision machining.
期刊介绍:
Precision Engineering - Journal of the International Societies for Precision Engineering and Nanotechnology is devoted to the multidisciplinary study and practice of high accuracy engineering, metrology, and manufacturing. The journal takes an integrated approach to all subjects related to research, design, manufacture, performance validation, and application of high precision machines, instruments, and components, including fundamental and applied research and development in manufacturing processes, fabrication technology, and advanced measurement science. The scope includes precision-engineered systems and supporting metrology over the full range of length scales, from atom-based nanotechnology and advanced lithographic technology to large-scale systems, including optical and radio telescopes and macrometrology.