CAE-ECM system for electrochemical technology of parts and tools

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298 J. Kozak et al. / Journal of Materials Processing Technology 107 (2000) 293±299Fig. 8. Experimental veri®cation of ECM with ¯at electrode. sinking feed rate V f ˆ 1mm=min; inlet electrolyte velocity w ˆ 10 m=s; outlet pressure p k ˆ 0:1 MPa; accuracy of calculated tool-electrode shape DF ˆ 2 mm.Calculated distributions of S, w, p, T, b and i as functionsof distance along the electrolyte ¯ow (with x ˆ 0 at the inlet)are shown in Fig. 10. The change in interelectrode gapwidth, S, results from blade's feather pro®le change aswell as from change of physical conditions along electrolyte¯ow.To evaluate in¯uence of ECM input parameters on interelectrodegap distribution (or, in other words, on workpieceshape error distribution) computer simulations for differentvalues of voltage, feed rate and inlet electrolyte velocitywere performed. Following values for these parameters wereused: inlet electrolyte velocity w ˆ 5, 10 and 15 m/s; voltage U ˆ 8, 12, 16 V; feed rate V f ˆ 0:75, 1.00, 1.50 mm/min.Fig. 9. Tool and blade pro®le.Some results for these simulations are shown in Fig. 11.The biggest values of gap width, S(x), occur at the pointwhere electrolyte exits that gap. They result from electrolytea conductivity change that is caused by temperature and gasfraction increase. Decrease of inlet velocity of electrolytecauses decrease of gap width at the electrolyte outlet.Gap width signi®cantly depends on pressure at the outletthat can be seen from graphs in Fig. 11 for p k ˆ 0:10 and0.15 MPa.Fig. 10. Calculated distributions of S, w, p, T, b and j as functions ofdistance along the electrolyte ¯ow.Fig. 11. Gap width for different input parameters.
J. Kozak et al. / Journal of Materials Processing Technology 107 (2000) 293±299 299Much more pronounced in¯uence on y coordinate of thepro®le have working voltage, U, and electrode feed rate, V f .As an example, in¯uence of feed rate on shape deviation isshown in Fig. 13.Results show that stabilization of these parameters isnecessary during machining. During ECM their valuesshould be maintained as close as possible to their nominalvalues, i.e. values that were used for tool-electrode design.Fig. 12. Distribution of pro®le deviations with respect to reference pro®leblp5 for different electrolyte velocities.5. ConclusionsThe presented CAE-ECM system can be useful forprocess planing for different variants of ECM. It can beused for process analysis, tool design and parameters selection.Presented results for ECM sinking showed goodagreement between theoretical predictions and actual experimentalresults. Conclusion can be made that this software``CAE-ECM'' has great potential to be used in industryapplications.AcknowledgementsFig. 13. Distribution of pro®le deviations with respect to reference pro®leblp5 for different electrode feed rates.Increase of outlet pressure causes signi®cant increase ofgap width that can be explained by decrease of concentrationof gas phase. Changes of pro®les in y direction with respectto reference pro®le, blp5, for different electrolyte velocitiesare shown in Fig. 12. Despite signi®cant changes of inletvelocity the maximum difference between pro®les wasrelatively small (
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CAE-ECM system for electrochemical technology of parts and tools

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