A Fundamental Study on Gas Film Formation and its Effect in Electrochemical Discharge Machining Process

电化学放电加工过程中气膜形成及其影响的基础研究

• 批准号: 1833112
• 负责人: Murali Sundaram
• 金额: $ 30.15万
• 依托单位: University of Cincinnati Main Campus
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-06-01 至 2023-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1833112&HistoricalAwards=false
• 关键词: Fundamental; Study; Gas; Film; Formation

Advanced engineering materials and alloys possess excellent physical properties. However, machining these materials by traditional methods is difficult due to their hardness, brittleness, and other characteristics, leading to increased tool wear and surface damage. This award supports a fundamental study of electrochemical discharge machining (ECDM) - a nontraditional process that improves the surface integrity of advanced engineering materials that are critical for the US economy and national security. Using modeling, simulation and experimental methods, the formation and stability of gas film in the ECDM of advanced materials will be studied. The topography, mechanical and tribological properties, and composition of the machined surface will be analyzed subsequently. The expected improvement in the machinability of a wide variety of both conductive and nonconductive materials will help in unleashing the full application potential of these materials in biomedical, electronic, automotive, and energy industries. Potential applications in these industries include hip joint prosthesis, electronics packaging, brake linings, and solid oxide fuel cells. The multi-disciplinary approach and results of this study can be extended to other electrical machining processes. The outcome of this project will be integrated into graduate and undergraduate courses, and training and learning within female and underrepresented minorities. The results of this research will be disseminated through peer-reviewed publications, presentations at professional society meetings, and YouTube videos.Through this research, fundamental knowledge on the mechanism of gas film formation and stability during the electrochemical discharge machining process will be generated by conducting analytical and experimental investigations to understand the effect of thickness and stability of the gas film on the surface integrity changes in machined parts. Critical insight into the rate of gas bubble formation, the rate of coalescence, and the gas film thickness will be acquired by molecular dynamics simulations to produce stable and thin gas film. Finite element simulations coupling electrical, chemical and thermal aspects of ECDM will be pursued to investigate the hydrodynamic behavior of boundary layers during gas film formation. Multi-physics based mathematical models will be developed to predict the gas film thickness, discharge energy and surface roughness in ECDM. Sensor fusion of optical and electrical feedback signals will be used in the experimental studies for in-process monitoring and control.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

先进的工程材料和合金具有优良的物理性能。然而，由于这些材料的硬度、脆性和其他特性，通过传统方法加工这些材料是困难的，导致增加的刀具磨损和表面损伤。该奖项支持电化学放电加工（ECDM）的基础研究-这是一种非传统工艺，可提高对美国经济和国家安全至关重要的先进工程材料的表面完整性。采用建模、仿真和实验相结合的方法，对先进材料电火花加工中气膜的形成和稳定性进行了研究。随后将分析加工表面的形貌、机械和摩擦学性能以及成分。各种导电和非导电材料的可加工性的预期改善将有助于释放这些材料在生物医学，电子，汽车和能源行业的全部应用潜力。这些行业的潜在应用包括髋关节假体、电子封装、制动衬片和固体氧化物燃料电池。多学科的方法和本研究的结果可以扩展到其他电加工过程。该项目的成果将纳入研究生和本科生课程，以及女性和代表性不足的少数群体的培训和学习。这项研究的结果将通过同行评议的出版物、专业协会会议上的演讲和YouTube视频传播。通过这项研究，通过分析和实验研究，了解气体膜的厚度和稳定性对表面完整性的影响，将产生关于电化学放电加工过程中气体膜形成和稳定性机理的基本知识加工零件的变化。通过分子动力学模拟，将获得对气泡形成速率、聚结速率和气膜厚度的关键洞察，以产生稳定且薄的气膜。有限元模拟耦合电，化学和热方面的ECDM将追求研究边界层的流体动力学行为在气膜形成。建立了基于多物理场的数学模型，用于预测电火花加工中的气膜厚度、放电能量和表面粗糙度。光电反馈信号的传感器融合将用于过程监测和控制的实验研究。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Predicting the sparks occurrence in electrochemical discharge machining by machine learning using convolutional neural networks

使用卷积神经网络通过机器学习预测电化学放电加工中火花的发生

• DOI: 10.1016/j.procir.2022.09.195
• 发表时间: 2022
• 期刊: Procedia CIRP
• 作者: Kale, Abhishek;Chen, Yu-Jen;Sundaram, Murali
• 通讯作者: Sundaram, Murali

Pulse electrochemical discharge machining of glass-fiber epoxy reinforced composite

• DOI: 10.1016/j.cirp.2019.04.113
• 发表时间: 2019
• 期刊: CIRP Annals
• 作者: M. Sundaram;Yu-Jen Chen;K. Rajurkar

A multiphase simulation study of electrochemical discharge machining of glass

玻璃电化学放电加工的多相模拟研究

• DOI: 10.1007/s00170-019-04318-5
• 发表时间: 2019
• 期刊: The International Journal of Advanced Manufacturing Technology
• 作者: Kolhekar, Ketaki;Sundaram, Murali
• 通讯作者: Sundaram, Murali

Creation of Functionally Graded Glass Channels by Electrochemical Discharge Machining Process: A Feasibility Study

通过电化学放电加工工艺创建功能梯度玻璃通道：可行性研究

• DOI: 10.1115/msec2021-63916
• 发表时间: 2021
• 期刊: ASME 2021 16th International Manufacturing Science and Engineering Conference
• 作者: Grisell, Andrea;Sundaram, Murali
• 通讯作者: Sundaram, Murali

Non-contact micromachining by a dynamic feed rate controlled electrochemical discharge machining process

通过动态进给速率控制的电化学放电加工工艺进行非接触式微加工

• DOI: 10.1177/09544054221147611
• 发表时间: 2022
• 期刊: Part B: Journal of Engineering Manufacture
• 作者: Shrestha, Hirdayesh;Chen, Yu-Jen;Sundaram, Murali
• 通讯作者: Sundaram, Murali