Gap effect in electrochemical jet machining

Liu，Weidong1; Li，Wentao1; Zhao，Yonghua2; Wang，Zhiping1; Guo，Zhiyong1

2023-08-04

10.1016/j.jmapro.2023.05.060

Journal of Manufacturing Processes   影响因子和分区

1526-6125

2212-4616

Electrochemical jet machining (EJM) is a young-generation micromachining and surface texturing technique with multiple merits. The materials removal function in EJM has traditionally been considered to be Gaussian-like and unaffected by changes in inter-electrode gap when maintaining a constant machining current. Nonetheless, phenomena that contradict this widely accepted perception are sometimes observed. In this paper, to clarify the inter-electrode gap effect in EJM, its impacts on flow field, electric field, and machined shape were studied by both experiments and simulation. With varied gaps ≥0.4 of nozzle diameter the jet profile keeps almost same and only its length changes, while narrowing the gap from 0.4 to 0.2 of nozzle diameter causes thinning of the jet-surrounding-film. Jet profile required for EJM cannot form with an overly tiny gap. In addition, the gap ≥0.6 of nozzle diameter features sufficiently long cylindrical jet portion that uniformly distributes the pass-through current density and eliminates the cathode-shape-determined electric field near nozzle to act on workpiece, resulting in constant materials removal function even though gap changes. With smaller gap the cathode-shape-determined electric field affects the anodic current density distribution and the materials removal function can be modulated by adjusting the gap, allowing EJM to generate geometry other than Gaussian-like profile. Furthermore, the influence of inter-electrode gap when using the specially-shaped nozzle was also investigated. With a small gap this method performs its ability in modulation of materials removal distribution by designing nozzle shapes, while a large gap such as ≥ nozzle diameter enables it to operate as a conventional nozzle.

Current density distribution Electrochemical jet machining Electrochemical machining Inter-electrode gap control Machined shape

SCI ; EI

英语

其他

National Key Research and Development Program of China[2021YFF0501700];Civil Aviation University of China[20221010294];Natural Science Foundation of Tianjin City[21JCQNJC00860];National Natural Science Foundation of China[52205504];

Engineering

Engineering, Manufacturing

WOS:001013916300001

ELSEVIER SCI LTD

20232214174076

Cathodes ; Current density ; Electrochemical cutting ; Electrochemical electrodes ; Nozzle design

Structural Design:408 ; Metal Cutting:604.1 ; Fluid Flow, General:631.1 ; Electricity: Basic Concepts and Phenomena:701.1 ; Electrochemistry:801.4.1 ; Chemical Reactions:802.2

2-s2.0-85160552470

Scopus

1.College of Aeronautical Engineering,Civil Aviation University of China,Tianjin,300300,China
2.Department of Mechanical and Energy Engineering,Southern University of Science and Technology,Shenzhen,518055,China

Liu，Weidong,Li，Wentao,Zhao，Yonghua,et al. Gap effect in electrochemical jet machining[J]. Journal of Manufacturing Processes,2023,99:652-662.

Liu，Weidong,Li，Wentao,Zhao，Yonghua,Wang，Zhiping,&Guo，Zhiyong.(2023).Gap effect in electrochemical jet machining.Journal of Manufacturing Processes,99,652-662.

Liu，Weidong,et al."Gap effect in electrochemical jet machining".Journal of Manufacturing Processes 99(2023):652-662.