Abstract
Jet electrochemical machining (Jet-ECM) is a significant prospective electrochemical machining process for the fabrication of micro-sized features. Traditionally and normally, the Jet-ECM process is carried out with its electrolytic jet being vertically impinged downstream against the workpiece. Therefore, other jet orientations, including a vertically upstream orientation and a horizontal orientation, have rarely been adopted. In this study, three jet orientations were applied to electrolytic jet machining, and the effect of jet orientations on machining characteristics was systemically investigated. Horizontal jet orientation is of great benefit in achieving accurate micro-sized features with excellent surface quality with either a static jet or a scanning jet for the Jet-ECM. On the other hand, the Jet-ECM with a horizontal jet orientation has a smaller material removal rate (MMR) than the ones with vertical jet orientations, which have almost the same MMR. It was found that an enhancement of machining localization and a reduction of MMR for horizontal jet electrochemical machining primarily results from an improvement of the mass-transfer field. The horizontal orientation of the jet is beneficial for the Jet-ECM processes to improve machining accuracy.
Highlights
Jet electrochemical machining (Jet-ECM) is a special form of electrochemical machining (ECM) using an electrolytic jet as a tool
In order to understand the effect of the jet orientation on the electrolyte flow behaviors and current density distribution during Jet-ECM, a simulation was conducted
In this a machining phase, the electrolyte film still exists in all the vertical jet orientations, but it disappears in the horizontal jet orientation, and, the left electrolyte is not observed on the workpiece surface
Summary
Jet electrochemical machining (Jet-ECM) is a special form of electrochemical machining (ECM) using an electrolytic jet as a tool. This traditional jet orientation is relatively easy to operate, a hydrodynamic jump frequently takes place at the workpiece, especially when the workpiece surface is large and planar, which generally results in an expansion of stray-current corrosion areas. In such a jet orientation, an electrolyte reflection phenomenon is often observed, which, as stated above, is one of the major causes that deteriorates machining localization for serious secondary stray-current corrosion. Simulation of Flow Field and Current Density Distribution of Electrolyte Jet With Different Orientation
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