Simulation Research of Small Holes by Combined Ultrasonic and Electrochemical Machining Based on CFX

Abstract:

A device was designed to study the small holes by the rotary combined ultrasonic and electrochemical machining, and the gap between cathode and anode in the processing was also analyzed. A three-dimensional model of flow field was developed in ANSYS CFX software based on FEM by the gas-liquid two-phase fluid cavitations model as well as the effect of rotary cathode and the vibrated cathode to the flow field was analyzed. The simulation showed that the pressure and the velocity of the electrolyte in the gap were oscillated by additional motion of cathode, which is helpful to the electrochemical machining. The comparison of rotary electrochemical machining and the rotary combined ultrasonic and electrochemical machining showed that the rotary combined ultrasonic and electrochemical machining has better ability of making small holes than that of rotary electrochemical machining

• Periodical: Key Engineering Materials (Volume 584)
• Pages: 60-66
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.584.60
• Online since: September 2013
• Authors: Ze Xiang Liu, Min Kang, Xiu Qing Fu
• Keywords: ANSYS CFX, Flow Field, Rotary Combined Ultrasonic and Electrochemical Machining, Small Holes

References

[1] M. Datta, Micro fabrication by electrochemical metal removal [J] IBM J. Res. Dev. 42 (5) (1998), pp.655-669. K.P. Rajurkar.

[2] D. Zhu. J.A. McGeough, etal. New Development in electrochemical machining [J]. Ann. CIRP 48(2) (1999), pp.567-579.

[3] K.P. Rajurkar, J. Kozak, B. Wei. Study of pulse electrochemical machining characteristics. Ann. CIRP42(1)(1993) , pp.231-234.

DOI: 10.1016/s0007-8506(07)62432-9

[4] B. Bhattacharyya, M. Malapati, J. Munda etal. Influence of tool vibration on machining performance in electrochemical micro-machining of Copper. International Journal of Machine Tools & Manufacture, 47(2007), pp.335-342.

DOI: 10.1016/j.ijmachtools.2006.03.005

[5] Fu XiangLin. Influence of ultrasonic on the electrochemical process [D]: Yang Zhou University, 2005, 6.

[6] Gan Xueping, Dai Xi, Zhang Chuanfu. Ultrasonic cavitations and its application in electrochemical [J], Sichuan Nonferrous Metals, 2001(3): 24-27.

[7] Chen Jingquan, Yao Suwei. Application of ultrasonic in electrochemical [J], Plating and Finishing, 2005, 27(1): 16-20.

[8] A Ruszaj, M Zybura, R Zurek etal. Some aspects of the electrochemical machining process supported by electrode ultrasonic vibrations optimization [J]. Proc. Instn Mech. Engrs Vol. 217 Part B:J. Engineering Manufacture, 2003: 1365-1371.

DOI: 10.1243/095440503322617135

[10] .

[9] M.S. Hewidy, S.J. Ebeid, T.A. El-Taweel, etal. Modelling the performance of ECM assisted by low frequency vibrations [J]. Journal of Materials Processing Technology, 2007(189): 466-472.

DOI: 10.1016/j.jmatprotec.2007.02.032

[10] Sebastian Skoczypiec. Research on ultrasonically assisted electrochemical machining process. www. Springerlink. com.

[11] Zhu Yongwei, Wang Zhanhe, Li Hongying etal. Machining Mechanism and Test Study on micro-machining of ECM Combined Ultrasonic Vibration [J]. China Mechanical Engineering, 2008, 19(15): 1786-1792.

[12] Ai Dongmei, Jia Zhixin. Status quo of porous processing technology [J]. Mechanical Engineers, 2000(1): 8-10.

[13] Xu Jiawen, Yun Naizhang, Wang Jianye. Electrochemical Machining Technique [M]. Beijing, National Defense Industry Pres, 2008, 7.

[14] Fan Zhijian, Li Xinzhong, and Wang Tiancheng etal. Electrochemical machining and composite electrochemical machining [M]. Beijing, National Defense Industry Press, (2008).

[15] Kang Min. The study on the technology of precision electrochemical contour evolution machining of integral impellers [D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2003, 3.