Energy distribution modulation by mechanical design for electrochemical jet processing techniques
Energy distribution modulation by mechanical design for electrochemical jet processing techniques
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DOI：
10.1016/j.ijmachtools.2017.05.005
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发表时间：
2017-11-01
影响因子：
14
通讯作者：
Clare, Adam T.
中科院分区：
文献类型：
--
作者：
Mitchell-Smith, Jonathon;Speidel, Alistair;Clare, Adam T.
对具有更高化学和几何复杂性的优化部件表面的需求日益增加，是先进表面生产所需制造技术的关键驱动力。目前的方法不能以高效和可扩展的方式在坚固的工程材料中创建复杂的表面。因此，需要克服这一点的先进制造技术。目前的技术受到分辨率、几何灵活性和能量输送模式的限制。通过解决电化学喷射技术的基本限制，通过调制的电流密度分布的机械设计，电化学喷射工艺方法的显着改进。开发了一个简化的2D随机模型，该模型能够改变电流密度分布，以评估电极尖端形状变化的影响。模拟表明，所得的轮廓被发现是可变的，从一个标准的喷嘴。然后对这些尖头修改进行实验测试，发现在机加工轮廓中可能存在高度变化。与标准轮廓相比，侧壁陡度增加了162%、切割轮廓的平底以及轮廓与表面相交半径的减小等改进使该工艺与传统的铣削轮廓类似。由于电极设计可以快速修改EJP被证明是一个灵活的过程，能够不同的和复杂的中尺度的轮廓创建。在电阻喷射调制方面的创新使电化学喷射工艺成为一种可行的、自上而下的单步方法，用于应用其他方法无法实现的复杂表面几何形状。
The increasing demand for optimised component surfaces with enhanced chemical and geometric complexity is a key driver in the manufacturing technology required for advanced surface production. Current methodologies cannot create complex surfaces in an efficient and scalable manner in robust engineering materials. Hence, there is a need for advanced manufacturing technologies which overcome this. Current technologies are limited by resolution, geometric flexibility and mode of energy delivery. By addressing the fundamental limitations of electrochemical jetting techniques through modulation of the current density distribution by mechanical design, significant improvements to the electrochemical jet process methods are presented. A simplified 2D stochastic model was developed with the ability to vary current density distribution to assess the effects of nozzle-tip shape changes. The simulation demonstrated that the resultant profile was found to be variable from that of a standard nozzle. These nozzle-tip modifications were then experimentally tested finding a high degree of variance was possible in the machined profile. Improvements such as an increase in side-wall steepness of 162% are achieved over a standard profile, flat bases to the cut profile and a reduction of profile to surface inter-section radius enable the process to be analogous to traditional milling profiles. Since electrode design can be rapidly modified EJP is shown to be a flexible process capable of varied and complex meso-scale profile creation. Innovations presented here in the modulation of resistance in-jet have enabled electrochemical jet processes to become a viable, top-down, single-step method for applying complex surfaces geometries unachievable by other means.