Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding
<p>Electrochemical chamfering schemes for small-sized inner intersecting holes. (<b>a</b>) Conventional electrochemical intersecting hole chamfering scheme; (<b>b</b>) built-in fixed cathode electrochemical intersecting hole chamfering scheme.</p> "> Figure 2
<p>Different shapes of cathode design. (<b>a</b>) Cylindrical cathode; (<b>b</b>) hemispherical cathode; (<b>c</b>) conical cathode; (<b>d</b>) concave cathode.</p> "> Figure 3
<p>Local contour change diagram of the workpiece. (<b>a</b>) Local contour of the workpiece corresponding to the conical cathode; (<b>b</b>) Local contour of the workpiece corresponding to the concave cathode.</p> "> Figure 4
<p>Variation of current density with time at the minimum gap on the workpiece surface. (<b>a</b>) <span class="html-italic">U</span> = 8 V; (<b>b</b>) <span class="html-italic">U</span> = 10 V; (<b>c</b>) <span class="html-italic">U</span> = 12 V; (<b>d</b>) <span class="html-italic">U</span> = 14 V.</p> "> Figure 5
<p>Experimental device and machining gap model. (<b>a</b>) Sectional view of the experimental device; (<b>b</b>) machining gap model.</p> "> Figure 6
<p>Schematic diagram of workpiece and cathode dimensions. (<b>a</b>) Workpiece size; (<b>b</b>) cathode size.</p> "> Figure 7
<p>Physical section of the cathode and workpiece.</p> "> Figure 8
<p>Variation of fillet radius with processing time.</p> "> Figure 9
<p>Fillet machining effect. (<b>a</b>) Original shape of workpiece; (<b>b</b>) 98 s; (<b>c</b>) 128 s; (<b>d</b>) 161 s; (<b>e</b>) 239 s; (<b>f</b>) 360 s.</p> ">
Abstract
:1. Introduction
2. Electrochemical Machining Scheme of an Inner Fillet
3. Simulation Study of Cathode Shape
3.1. Cathode Shape Design
3.2. Influence of Cathode Shape on Machining
3.2.1. Influence of Cathode Shape on the Electric Field Distribution
3.2.2. Influence of Cathode Shape on Machining Efficiency
4. Experimental Research on the Electrochemical Machining of an Inner Fillet
4.1. Cathode Shape Design
4.2. Experimental Conditions
4.3. Experimental Results and Discussion
4.3.1. Influence of Machining Voltage on the Machining Effect
4.3.2. Fillet Radius as a Function of Processing Time
4.4. Processing Example
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Comparison Items | Conventional Electrochemical Machining Solution for Intersecting-Hole Chamfering | Built-In Fixed Cathode Electrochemical Machining Solution for Intersecting-Hole Chamfering |
---|---|---|
Small hole diameter | Limited by the diameter of the cathode, the rigidity of the cathode is insufficient, and it is suitable for processing intersecting holes with larger diameters. | The cathode is outside the small hole, the rigidity of the cathode is not limited by the diameter size, and the processing stability is good. |
Flow field state | The cathode occupies small holes, and the uniformity of the electrolyte flow field is affected. | The electrolyte flow field is uniform, which is beneficial for improving the processing quality. |
Electric field state | The manufacturing process of the cathode is poor, the processing part is difficult to form into a specific shape, and the electric field distribution state is not conducive to the formation of fillets. | The manufacturing process of the cathode is good, the processing part is easy to form into a specific shape, and the electric field distribution state is conducive to the formation of fillets. |
Rounded shape | The gap of the electrolyte outlet changes, and the shape of the fillet is not easy to control. | The machining gap is symmetrical on both sides of the intersecting line, and the shape of the fillet is easily controllable. |
Processing Time | Cylindrical Cathode | Hemispherical Cathode | Conical Cathode | Concave Cathode |
---|---|---|---|---|
0 s | ||||
60 s | ||||
120 s | ||||
240 s |
Experimental Conditions | Parameters/Units | Value |
---|---|---|
Cathode | Material | 304 stainless steel |
Size (mm) | Figure 6b | |
Power Supply | Voltage range (V) | 0~36 |
Current range (A) | 0~200 | |
Workpiece | Material | 304 stainless steel |
Size (mm) | Figure 6a | |
Electrolyte | Main components | NaNO3 + Water |
Mass fraction | 15% | |
Main parameter | Initial machining clearance (mm) | 0.7 |
Processing time (s) | 0~480 | |
Processing voltage (V) | 4~14 | |
Measuring instrument | Industrial camera | UV20S |
Machining Voltage (V) | Processing Phenomenon |
---|---|
4 | Few bubbles appear; electrolysis products can be discharged in time; fillets are regular in shape. |
6 | Small amounts of bubbles appear; electrolysis products can be discharged in time; fillets are regular in shape. |
8 | Small amounts of bubbles appear; electrolysis products can be discharged in time; fillets are regular in shape. |
10 | Many bubbles appear; small amounts of electrolysis products remain between the insulating sleeves and the workpiece, which does not affect normal processing; fillets are regular in shape. |
12 | Many bubbles appear; small amounts of electrolysis products remain between the insulating sleeves and the workpiece; the shape of the fillet is deformed, and the hole walls on both sides of the fillet are unevenly corroded. |
14 | A large number of bubbles appear; a large number of electrolysis products remain between the insulating sleeves and the workpiece; the shape of the fillet is deformed, and the hole walls on both sides of the fillet are severely corroded. |
df | SS | MS | F | Significance F | ||
---|---|---|---|---|---|---|
Regression analysis | 2 | 1.4675 | 0.7338 | 1017.89 | 5.2 × 10−15 | |
Residuals | 13 | 0.0094 | 0.0007 | |||
Total | 15 | 1.4769 | ||||
Coefficients | Standard Error | tStat | p-Value | Lower 95.0% | Upper 95.0% | |
Intercept | 0.0122 | 0.0229 | −0.5327 | 0.6032 | −0.037 | 0.062 |
t2 | −4.6 × 10−6 | 3.9 ×10−7 | −11.567 | 3.2 × 10−8 | −5.4 × 10−6 | −3.7 × 10−6 |
t | 0.0044 | 2.1 × 10−4 | 21.467 | 1.6 × 10−11 | 0.004 | 0.005 |
Intersecting Hole Fillet Radius R (mm) | Processing Time t (s) | |
---|---|---|
Calculated Value | Test Value | |
0.4 | 98.22 | 98 |
0.5 | 127.99 | 128 |
0.6 | 160.53 | 161 |
0.8 | 238.53 | 239 |
1.0 | 359.96 | 360 |
Intersecting Hole Fillet Radius R (mm) | Calculated Processing Time (s) | Radius Value of Three Repeated Experiments (mm) | Error (%) | Average Error (%) |
---|---|---|---|---|
0.4 | 98 | 0.415 | 3.8 | 2.1 |
0.410 | 2.5 | |||
0.400 | 0 | |||
0.5 | 128 | 0.510 | 2 | 3.3 |
0.480 | 4 | |||
0.520 | 4 | |||
0.6 | 161 | 0.620 | 3.3 | 4.2 |
0.570 | 5 | |||
0.625 | 4.5 | |||
0.8 | 239 | 0.810 | 1.3 | 2.7 |
0.775 | 3.1 | |||
0.830 | 3.8 | |||
1.0 | 360 | 1.005 | 0.5 | 2.2 |
0.980 | 2 | |||
1.040 | 4 |
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Pang, G.; Yan, Z.; Zhu, X.; Fan, S. Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding. Appl. Sci. 2022, 12, 10666. https://doi.org/10.3390/app122010666
Pang G, Yan Z, Zhu X, Fan S. Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding. Applied Sciences. 2022; 12(20):10666. https://doi.org/10.3390/app122010666
Chicago/Turabian StylePang, Guibing, Zhaobin Yan, Xiaofei Zhu, and Shuangjiao Fan. 2022. "Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding" Applied Sciences 12, no. 20: 10666. https://doi.org/10.3390/app122010666