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Analysis and control of inter-electrode gap during leveling process in counter-rotating electrochemical machining

Chinese Journal of Aeronautics 2019年第11期32卷 2557-2565页

作者： Dengyong WANG Jinzheng LI Bin HE Di ZHU College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology Nanjing 210016China

The inter-electrode gap(IEG) is an essential parameter for the anode shaping process in electrochemical machining(ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of an oval anode workpiece in counter-rotating ECM(CRECM)is investigated. The variation of the minimum IEG is analyzed theoretically, and the results indicate that rather than reaching equilibrium, the minimum IEG in CRECM expands constantly when a constant feed speed is used for the cathode tool. This IEG expansion leads to a poor localization effect and has an adverse influence on the roundness of the machined workpiece. To maintain a small constant IEG in CRECM, a variable feed speed is used for the cathode based on a fitted equation. The theoretical results show that the minimum IEG can be controlled at a small value by using an accelerated feed speed. Experiments have been conducted using a specific experimental apparatus in which the cathode tool is designed as a combined structure of two sectors and a thin sheet. By detecting the machining currents flowing through the minimum IEG, how the latter varies is obtained indirectly. The results indicate that using an accelerated feed speed is effective for controlling the IEG, thereby improving the roundness of the machined workpiece.

关键词： Counter-rotating Electrochemical machining inter-electrode gap Leveling process Variable feed speed

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Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method

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Chinese Journal of Aeronautics 2016年第2期29卷 534-541页

作者： Wang Dengyong Zhu Zengwei Wang Hongrui Zhu Di Nanjing University of Aeronautics and Astronautics Nanjing 210016 China Nanjing Institute of Technology Nanjing 211167 China

In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.

关键词： Counter-rotating Convex shaping process Electrochemical machining Finite element method inter-electrode gap

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维普期刊数据库

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AUTOREGRESSIVE MODEL AND POWER SPECTRUM CHARATERISTICS OF CURRENT SIGNAL IN HIGH FREQUENCY GROUP PULSE MICRO-ELECTROCHEMICAL MACHINING

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Chinese Journal of Mechanical Engineering 2006年第2期19卷 260-264页

作者： TANG Xinglun ZHANG Zhijing ZHOU Zhaoying YANG Xiaodong Department of Precision Instrument ＆ Mechanics Tsinghua UniversityBeijing 100084 China School of Mechanical ＆ Vehicle Engineering Beijing Institute of TechnologyBeijing 100084 China Equipment ＆ Energy Department Guizhou Branch of Aluminum Co. Ltd.Guiyang 550014 China

The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining （HGPECM） is mainly discussed. The auto-regressive（AR） model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, i.e. the white noise response of the Green＇s function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum（CPS）, to the current signals related to the different inter-electrode gap size in the range of 0～5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.

关键词： Electrochemical machining inter-electrode gap Autoregressive(AR) model Power spectrum

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