Modeling and Verification of Interelectrode Gap in Electrochemical Machining With Passivating Electrolyte
Modeling and Verification of Interelectrode Gap in Electrochemical Machining With Passivating Electrolyte
复制标题
DOI：
10.1115/imece1999-0719
复制
发表时间：
1999-11
期刊：
影响因子：
--
通讯作者：
D. Zhu;K. Rajurkar
中科院分区：
文献类型：
--
作者：
D. Zhu;K. Rajurkar
由于在工具设计、监测和控制以及污泥产生和处置方面的困难，电解加工技术的工业应用受到限制。对电极间隙(即工具电极和工件电极之间的间隙)进行准确的建模和预测是将这些困难降至最低的最重要步骤之一。电极间隙分布取决于电场分布，电场分布是电化学溶解过程中许多工艺参数在空间和时间上变化的函数。本文提出了一种确定间隙分布的模型和数值方法。该模型的基础是确定电极间隙中的电场，并找到满足电位分布的拉普拉斯方程和所有其他边界条件的阴极(工具)边界，以获得所需的工件形状。该方法考虑了电解加工性的变化，适用于非钝化和钝化电解液的电解加工。该方法不需要迭代重新设计过程，具有良好的收敛性能和计算精度。使用专门开发的电解槽和工业规模的电解加工系统进行了验证实验。理论结果与实验结果吻合较好。
The industrial applications of Electrochemical Machining (ECM) technology are limited due to difficulties in tool design, monitoring and control, and sludge generation and disposal. An accurate modeling and prediction of interelectrde gap (i.e. the gap between tool electrode and workpiece electrode) is one of the most important steps to minimize these difficulties. The interelectrode gap distribution depends on electric field distribution which is a function of many process parameters varying in space and time during electrochemical dissolution process. This paper proposes a model and numerical approach to determine the gap distribution. The model is based on determining the electric field in the interelectrode gap and finding a cathode (tool) boundary which will satisfy the Laplace Equation for potential distribution and all other boundary conditions to achieve the desired workpiece shape. The proposed method incorporates the variation of electrochemical machinability and, hence, is applicable to ECM with both non-passivating and passivating electrolytes. The proposed method does not require iterative redesign process, therefore, it provides excellent convergence and computing accuracy. The verification experiments have been conducted using a specially developed electrolytic cell and an industrial scale ECM system. A close agreement has been observed between theoretical and experimental results.