Improvement of machining consistency during through-mask electrochemical large-area machining
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摘要
Electrochemical machining(ECM) is an important machining technique for the aeronautical manufacturing industry. Through-mask ECM is a form of ECM for machining metal parts with a hole array. In order to extend the machining area, a serpentine flow channel with multiple curves was used for through-mask ECM. With the extension of the flow channel, ensuring a machining consistency along the flow channel has been a challenge. The electrolyte conductivity is the main factor affecting the machining consistency. To analyze the change rules of the electrolyte conductivity, variations in the bubble rate and the temperature of the electrolyte in the electrolyte flow were explored under different power sources. Results indicate that pulse-power machining can reduce variations in the bubble rate and the temperature in the serpentine flow channel, and then the electrolyte conductivity can be stabilized within a very small range. Experiments using through-mask ECM were conducted in two types of power sources. Experimental results support the importance of pulse-power machining. A 14×28 hole array with a 2.5 mm diameter was fabricated by a pulsed power source. The aperture deviation of the hole array is less than 0.05 mm, and the roundness deviation is less than 15 lm when fabricated with pulse machining.
Electrochemical machining(ECM) is an important machining technique for the aeronautical manufacturing industry. Through-mask ECM is a form of ECM for machining metal parts with a hole array. In order to extend the machining area, a serpentine flow channel with multiple curves was used for through-mask ECM. With the extension of the flow channel, ensuring a machining consistency along the flow channel has been a challenge. The electrolyte conductivity is the main factor affecting the machining consistency. To analyze the change rules of the electrolyte conductivity, variations in the bubble rate and the temperature of the electrolyte in the electrolyte flow were explored under different power sources. Results indicate that pulse-power machining can reduce variations in the bubble rate and the temperature in the serpentine flow channel, and then the electrolyte conductivity can be stabilized within a very small range. Experiments using through-mask ECM were conducted in two types of power sources. Experimental results support the importance of pulse-power machining. A 14×28 hole array with a 2.5 mm diameter was fabricated by a pulsed power source. The aperture deviation of the hole array is less than 0.05 mm, and the roundness deviation is less than 15 lm when fabricated with pulse machining.
Electrochemical machining(ECM) is an important machining technique for the aeronautical manufacturing industry. Through-mask ECM is a form of ECM for machining metal parts with a hole array. In order to extend the machining area, a serpentine flow channel with multiple curves was used for through-mask ECM. With the extension of the flow channel, ensuring a machining consistency along the flow channel has been a challenge. The electrolyte conductivity is the main factor affecting the machining consistency. To analyze the change rules of the electrolyte conductivity, variations in the bubble rate and the temperature of the electrolyte in the electrolyte flow were explored under different power sources. Results indicate that pulse-power machining can reduce variations in the bubble rate and the temperature in the serpentine flow channel, and then the electrolyte conductivity can be stabilized within a very small range. Experiments using through-mask ECM were conducted in two types of power sources. Experimental results support the importance of pulse-power machining. A 14×28 hole array with a 2.5 mm diameter was fabricated by a pulsed power source. The aperture deviation of the hole array is less than 0.05 mm, and the roundness deviation is less than 15 lm when fabricated with pulse machining.
引文
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9.Chen XZ,Qu NS,Li H,Xu ZY.Electrochemical micromachining of micro-dimple arrays using a polydimethylsiloxane(PDMS)mask.J Mater Process Technol 2016;229:102-10.
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11.Duy VN,Lee J,Kim K,Ahn J,Park S,Kim T,et al.Dynamic simulations of under-rib convection-driven flow-field configurations and comparison with experiment in polymer electrolyte membrane fuel cells.J Power Sources 2015;293(3):447-57.
12.Chang DH,Wu SY.The effects of channel depth on the performance of miniature proton exchange membrane fuel cells with serpentine-type flow fields.Int J Hydrogen Energy 2015;40(35):11659-67.
13.Rajurkar KP,Zhu D,Mcgeough JA,Kozak J,Silva AD.New developments in electro-chemical machining.CIRP Ann 1999;48(2):567-79.
14.Bhattacharyya B,Mitra S,Boro AK.Electrochemical machining:new possibilities for micromachining.CIM-INT Manuf 2002;18(3-4):283-9.
15.He HD,Qu NS,Zeng YB,Tong PZ.Improvement of hydrogen bubbles detaching from the tool surface in micro wire electrochemical machining by applying surface microstructures.J Electrochem Soc 2017;164(9):E248-59.
16.Clark WG,Mcgeough JA.Temperature distribution along the gap in electrochemical machining.J Appl Electrochem 1977;7(4):277-86.
17.Fang X,Qu N,Zhang Y,Xu Z,Zhu D.Effects of pulsating electrolyte flow in electrochemical machining.J Mater Process Technol 2014;214(1):36-43.
2.Shokrani A,Dhokia V,Newman ST.Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids.Int J Mach Tool Manuf 2012;57(2):83-101.
3.Gao YY,Ma JW,Jia ZY.Tool path planning and machining deformation compensation in high-speed milling for difficult-tomachine material thin-walled parts with curved surface.Int J Adv Manuf Technol 2016;84(9-12):1757-67.
4.Lohrengel MM,Rataj KP,Mu¨nninghoff T.Electrochemical machining-mechanisms of anodic dissolution.Electrochim Acta2016;201:348-53.
5.Hackert-Oscha¨tzchen M,Paul R,Kowalick M,Kuhn D,Meichsner G,Zinecker M,et al.Characterization of an electrochemical machining process for precise internal geometries by multiphysics simulation.Proc CIRP 2017;58:175-80.
6.Kern P,Michler J,Veh J.New developments in through-mask electrochemical micromachining of titanium.J Micromech Microeng 2007;17(6):1168-77.
7.Kwon GJ,Sun HY,Sohn HJ.Wall profile developments in through-mask electrochemical micromachining of invar alloy films.J Electrochem Soc 1995;142(9):3016-20.
8.Madore C,Piotrowski O,Landolt D.Through-mask electrochemical micromachining of titanium.J Electrochem Soc 1999;146(7):2526-32.
9.Chen XZ,Qu NS,Li H,Xu ZY.Electrochemical micromachining of micro-dimple arrays using a polydimethylsiloxane(PDMS)mask.J Mater Process Technol 2016;229:102-10.
10.Zhu D,Qu NS,Li HS,Zeng YB,Li DL,Qian SQ.Electrochemical micromachining of microstructures of micro hole and dimple array.CIRP Ann 2009;58(1):177-80.
11.Duy VN,Lee J,Kim K,Ahn J,Park S,Kim T,et al.Dynamic simulations of under-rib convection-driven flow-field configurations and comparison with experiment in polymer electrolyte membrane fuel cells.J Power Sources 2015;293(3):447-57.
12.Chang DH,Wu SY.The effects of channel depth on the performance of miniature proton exchange membrane fuel cells with serpentine-type flow fields.Int J Hydrogen Energy 2015;40(35):11659-67.
13.Rajurkar KP,Zhu D,Mcgeough JA,Kozak J,Silva AD.New developments in electro-chemical machining.CIRP Ann 1999;48(2):567-79.
14.Bhattacharyya B,Mitra S,Boro AK.Electrochemical machining:new possibilities for micromachining.CIM-INT Manuf 2002;18(3-4):283-9.
15.He HD,Qu NS,Zeng YB,Tong PZ.Improvement of hydrogen bubbles detaching from the tool surface in micro wire electrochemical machining by applying surface microstructures.J Electrochem Soc 2017;164(9):E248-59.
16.Clark WG,Mcgeough JA.Temperature distribution along the gap in electrochemical machining.J Appl Electrochem 1977;7(4):277-86.
17.Fang X,Qu N,Zhang Y,Xu Z,Zhu D.Effects of pulsating electrolyte flow in electrochemical machining.J Mater Process Technol 2014;214(1):36-43.