Skip to main content

Advertisement

SpringerLink
Log in

Optimization and experimental study on cathode structure of electrochemical machining titanium alloy inner helix

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In order to solve the problem of gap flow field divergence and poor forming accuracy in the electrochemical machining (ECM) titanium alloy inner helix, the pull reverse flow and pull downstream cathode physical models as well as the simulation models of machining gap flow field are established respectively in this paper. Different inclination angles of the liquid supply hole effected on the pull downstream cathode rotational flow field uniformity were explored. The results showed that the gap flow field distribution of the pull downstream cathode is better than pull reverse flow cathode, and the distribution of the rotational flow field formed when the inclination angle of the liquid supply hole achieves 40° is relatively uniform. Under the condition of voltage 12 V, cathode feed speed 15 mm/min, composite electrolyte 3%NaCl + 10%NaNO3 + 6%NaClO3, electrolyte temperature 30 °C, and electrolyte inlet pressure 2 MPa, the 800-mm length of titanium alloy inner helix sample was machined stably and reliably by the pull downstream cathode structure, which surface roughness is Ra0.8 μm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

Data availability

The authors confirm that the data supporting the findings of this study are available within the article.

References

  1. Davydov AD, Kabanova TB, Volgin VM (2017) Electrochemical machining of titanium. Review. Russ J Electrochem 53(9):941–965

    Article  Google Scholar 

  2. Hou N, Wang MH, Wang B, Zheng YH, Zhou SY, Song C (2022) Fundamental functions of physical and chemical principles in the polishing of titanium alloys: mechanisms and problems. Int J Adv Manuf Technol 118(7–8):2079–2097

    Article  Google Scholar 

  3. Hourmand M, Sarhan AAD, Sayuti M, Hamdi MA (2021) Comprehensive review on machining of titanium alloys. Arab J Sci Eng 46(8):7087–7123

    Article  Google Scholar 

  4. Niinomi M (2018) Recent progress in research and development of metallic structural biomaterials with mainly focusing on mechanical biocompatibility. Mater Trans 59(1):1–13

    Article  Google Scholar 

  5. Pasang T, Budiman AS, Wang JC, Jiang CP, Boyer R, Williams J, Misiolek WZ (2023) Additive manufacturing of titanium alloys-Enabling re-manufacturing of aerospace and biomedical components. Microelectron Eng 270(1):111935

  6. Takahashi M, Sato K, Togawa G, Takada Y (2022) Mechanical properties of Ti-Nb-Cu alloys for dental machining applications. J Funct Biomater 13(4):263

  7. Williams JC, Boyer RR (2020) Opportunities and issues in the application of titanium alloys for aerospace components. Metals 10(6):705

  8. Du YJ, Yue CX, Li XC, Liu XL, Liang SY (2021) Research on breakage characteristics in side milling of titanium alloy with cemented carbide end mill. Int J Adv Manuf Technol 117(11–12):3661–3679

    Article  Google Scholar 

  9. Pan TH, Zhang J, Zhang X, Zhao WH, Zhang HJ, Lu BH (2022) Milling force coefficients-based tool wear monitoring for variable parameter milling. Int J Adv Manuf Technol 120(7–8):4565–4580

    Article  Google Scholar 

  10. Spieser A, Ivanov A (2013) Recent developments and research challenges in electrochemical micromachining (AμECM). Int J Adv Manuf Technol 69(1–4):563–581

    Article  Google Scholar 

  11. Jia JL, Xu TC, Zhong L, Xu J, Zhou XY, Li SC (2022) Analysis of flow field for ECM square deep hole with two-section square cone combination cathode. Int J Adv Manuf Technol 121(7–8):5617–5634

    Article  Google Scholar 

  12. Wang YD, Xu ZY, Liu J, Zhang A, Xu ZL, Meng DM, Zhao JB (2021) Study on flow field of electrochemical machining for large size blade. Int J Mech Sci 190:106018

  13. Yang F, Zhang J, Zhao S, Guo CA (2020) Analysis of flow field for electrochemical machining deep spiral hole with gradually changing groove section. Int J Adv Manuf Technol 107(7–8):3267–3275

    Article  Google Scholar 

  14. Yuan K, Wu HC, Cao G, Nie L, Ji B (2022) Design and optimization of cathode for ECM of high-speed steel roll material based on multi-physics field coupling analysis. Int J Adv Manuf Technol 121(11–12):7983–7995

    Article  Google Scholar 

  15. van der Velden T, Ritzert S, Reese S, Waimann J (2023) A novel numerical strategy for modeling the moving boundary value problem of electrochemical machining. Int J Numer Methods Eng 124(8):1856–1882

    Article  MathSciNet  Google Scholar 

  16. Mishra DK, Singh T, Dixit P (2022) Cathode shape prediction for uniform electrochemical dissolution of array tools for ECDM applications. Mater Manuf Process 37(12):1463–1473

    Article  Google Scholar 

  17. Chen YL, Lin H, Cai B, Chen PX, Chen Q (2022) The influence of electrode hole structure on cross groove electrochemical machining. Int J Adv Manuf Technol 118(1–2):291–301

    Article  Google Scholar 

  18. Chen WW, Ge ZH, Zhu YW, Hou Y (2022) Simulation and experimental study on influence of flow field parameters on electrochemical machining performance. Int J Electrochem Sci 17(9):220910

  19. Chen YL, Li X, Liu JY, Zhang YC (2022) Multiphysics numerical simulation of the transient process in electrochemical machining. Mechanika 28(5):417–422

    Article  Google Scholar 

  20. Chen YL, Li X, Zhang YC, Liu JY (2022) Effects of machining parameters on electrochemical multi-field coupling. Mechanika 28(6):473–480

    Article  Google Scholar 

  21. He YF, Gan WM, Yin FH, Zhao JS, Xu B, Yu Q, Yang L (2020) Multi-physical field coupling for vibration feed electrochemical machining of diamond-shaped hole in titanium alloy. Int J Adv Manuf Technol 106(3–4):1409–1420

    Article  Google Scholar 

  22. Ren MZ, Zhu D, Hou ZH, Lei GP (2022) Investigation on multi-physical field simulations of blade ECM using vertical flow. Int J Adv Manuf Technol 123(11–12):4251–4263

    Article  Google Scholar 

  23. Mahdavinejad R, Hatami M (2008) On the application of electrochemical machining for inner surface polishing of gun barrel chamber. J Mater Process Technol 202(1–3):307–315

    Article  Google Scholar 

  24. Zhao JS, Lv YM, Wang F, Yang ZW, Liu DM, Fan YT, He YF (2018) Experimental research on process stability in pulsed electrochemical machining of deep narrow grooves with high length-width ratio. Int J Adv Manuf Technol 96(5–8):2245–2256

    Article  Google Scholar 

  25. Tang L, Fan ZJ, Zhao GG, Yang F, Yang S (2016) High aspect ratio deep spiral tube electrochemical machining technology. Procedia CIRP 42:407–411

    Article  Google Scholar 

  26. Tang L, Feng X, Zhai KG, Ji Y, Wang Z, Lei QB, Ren L (2019) Gap flow field simulation and experiment of electrochemical machining special-shaped inner spiral tube. Int J Adv Manuf Technol 100(9–12):2485–2493

    Article  Google Scholar 

  27. Tang L, Yang WL, Shi CJ, Zhang LF, Zhai KG (2022) Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole. Int J Adv Manuf Technol 120(5–6):3901–3910

    Article  Google Scholar 

  28. Tang L, Zheng YZ, Shi CJ, Zhang LF, Wang Z (2022) Analysis and test of conductive shaft of large horizontal NC ECM machine tool. Int J Adv Manuf Technol 120(11–12):7827–7841

    Article  Google Scholar 

  29. Zhai KG, Tang L, Liu J, Zhang XY, Yan YN, Feng X (2021) Study on improving the surface roughness of multi-stage internal cone hole by rotating magnetic field assisted electrochemical machining. Int J Adv Manuf Technol 115(4):1227–1236

    Article  Google Scholar 

  30. Liu Y, Qu NS, Qiu Z (2022) Flow field simulation and experimental investigation on macro electrolyte jet electrochemical turning of TB6 titanium alloy. Int J Adv Manuf Technol 120(3–4):2617–2632

    Article  Google Scholar 

  31. Meng JB, Wang SK, Guan QY, Dong XJ, Li HM, Li L, Zhao GY, Zhao YG (2022) Experimental investigation on simultaneous machining of EDM and ECM of Ti6Al4V with different abrasive materials and particle sizes. Int J Adv Manuf Technol 122(5–6):2307–2317

    Article  Google Scholar 

  32. Zhang SS, Wang LZ, Zhou JP, Dai XY, Xu Y, Qiu WX, Wang SS, Hu GY (2022) SEAM-ECM jet milling TC4 titanium alloy using gas-liquid mixed medium. Int J Adv Manuf Technol 119(11–12):6979–6993

    Article  Google Scholar 

Download references

Funding

This work was financially supported by the Shaanxi Provincial Key Research and Innovation Team Project (Grant No. 2023-CX-TD-24), Shaanxi University Youth Innovation Team Project (Grant No. 20201020), Shaanxi Provincial Department of Education Youth Innovation Team Construction Research Project (Grant No. 21JP054, No. 22JP032), Xi’an Science and Technology Plan Scientist and Engineer Team Construction Project (Grant No. 23KGDW0003-2022), Shaanxi Provincial Department of Education Industrialization Cultivation Project (Grant No. 23JC041), and Shaanxi Provincial Youth Innovation Team Project (Grant No. 23JP069).

Author information

Authors and Affiliations

  1. School of Mechatronics Engineering, Xi’an Technological University, 710021, Xi’an, People’s Republic of China

    Lin Tang, Yuanchao Ma & Jingjing Zhang

  2. R&D Center, Xi’an Space Engine Company Limited, 710100, Xi’an, People’s Republic of China

    Runrong Xue & Youfeng Bo

  3. China National Heavy Machinery Research Institute Co., Ltd, 710018, Xi’an, People’s Republic of China

    Jun Zhang

Authors
  1. Lin Tang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuanchao Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Runrong Xue
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Youfeng Bo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jingjing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jun Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study conception and design. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Lin Tang.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Highlights

• The performance of titanium alloy is complex and very sensitive to the change of processing parameters and the accuracy is difficult to control, which brings great difficulties to manufacturing.

• The physical models of pull reverse flow and pull downstream cathode were established and studied the gap flow field distribution.

• In order to improve the forming accuracy of electrochemical machining we proposed a rotational flow field electrochemical machining method.

• The experimental results were consistent with the results of the machining gap flow field simulation.

• Using pull downstream cathode and rotational flow field for electrochemical machining is an effective method to improve the forming accuracy.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Tang, L., Ma, Y., Xue, R. et al. Optimization and experimental study on cathode structure of electrochemical machining titanium alloy inner helix. Int J Adv Manuf Technol 130, 1141–1149 (2024). https://doi.org/10.1007/s00170-023-12757-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12757-4

Keywords

Search

Navigation