Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219
Electrochemical milling is an ideal technique for machining large-scale 3D structures that consist of aerospace aluminum alloys. The distribution of the electric and flow fields are vital to the quality of the machined surface, and the structures of the inner flow channel and bottom outlet have diff...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-02-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/17/4/829 |
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| author | Shukai Fan Xiaoyun Hu Junzhi Shen Xin Ma Hansong Li |
| author_facet | Shukai Fan Xiaoyun Hu Junzhi Shen Xin Ma Hansong Li |
| author_sort | Shukai Fan |
| collection | DOAJ |
| description | Electrochemical milling is an ideal technique for machining large-scale 3D structures that consist of aerospace aluminum alloys. The distribution of the electric and flow fields are vital to the quality of the machined surface, and the structures of the inner flow channel and bottom outlet have different effects on the electric and flow fields on the machining surface. In this study, two specialized structures of a tool cathode were optimized by simulating the electric and flow fields, and a reasonable design basis for the tool cathode was obtained. Based on this, an ECM experiment was performed with the same machining parameters using different tools, and a 20 mm × 20 mm plane was machined. The experimental results showed that using an appropriate tool cathode can create ideal flow and electric fields, resulting in better processing. After optimizing, the machining plane arithmetic mean deviation decreased by 43% (from 14.050 μm to 6.045 μm), and the region elevation difference decreased by 52% (from 105.93 μm to 55.17 μm). |
| first_indexed | 2024-03-07T22:24:19Z |
| format | Article |
| id | doaj.art-fb1d775cef524f7a9346f76b1884cc26 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-07T22:24:19Z |
| publishDate | 2024-02-01 |
| publisher | MDPI AG |
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| series | Materials |
| spelling | doaj.art-fb1d775cef524f7a9346f76b1884cc262024-02-23T15:25:30ZengMDPI AGMaterials1996-19442024-02-0117482910.3390/ma17040829Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219Shukai Fan0Xiaoyun Hu1Junzhi Shen2Xin Ma3Hansong Li4College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaCollege of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, ChinaElectrochemical milling is an ideal technique for machining large-scale 3D structures that consist of aerospace aluminum alloys. The distribution of the electric and flow fields are vital to the quality of the machined surface, and the structures of the inner flow channel and bottom outlet have different effects on the electric and flow fields on the machining surface. In this study, two specialized structures of a tool cathode were optimized by simulating the electric and flow fields, and a reasonable design basis for the tool cathode was obtained. Based on this, an ECM experiment was performed with the same machining parameters using different tools, and a 20 mm × 20 mm plane was machined. The experimental results showed that using an appropriate tool cathode can create ideal flow and electric fields, resulting in better processing. After optimizing, the machining plane arithmetic mean deviation decreased by 43% (from 14.050 μm to 6.045 μm), and the region elevation difference decreased by 52% (from 105.93 μm to 55.17 μm).https://www.mdpi.com/1996-1944/17/4/829aerospace aluminum 2219electrochemical millingrectangular cathodecathode design |
| spellingShingle | Shukai Fan Xiaoyun Hu Junzhi Shen Xin Ma Hansong Li Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 Materials aerospace aluminum 2219 electrochemical milling rectangular cathode cathode design |
| title | Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 |
| title_full | Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 |
| title_fullStr | Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 |
| title_full_unstemmed | Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 |
| title_short | Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219 |
| title_sort | machining surface improvement through electric and flow field adjustments in flying electrochemical milling of aa 2219 |
| topic | aerospace aluminum 2219 electrochemical milling rectangular cathode cathode design |
| url | https://www.mdpi.com/1996-1944/17/4/829 |
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