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Investigation of leveling ability improvement in pulse electrochemical machining for aero structural components

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Abstract

In electrochemical machining of aero structural components, the allowance distribution between the blank and the model is generally not uniform, which may influence the final precision of components. However, proper leveling can reduce the negative impacts of this nonuniformity and enhance machining accuracy. This paper proposes a mathematical model for pulse electrochemical machining (ECM) to simulate the corrosion process in order to improve the leveling. Several machining parameters, such as power voltage, pulse duty, and frequency, are considered to optimize the leveling ratio. The optimal parameters are obtained from the simulation. The simulation results show that the leveling ratio improves with the decrease of pulse duty and voltage and the increase of frequency. Furthermore, the pulse duty has a more significant effect on the leveling ability than the voltage and the frequency. In addition, verified experiments are carried out and the results are consistent with the simulation. It indicates that the proposed model is effective and can be used for complex structural components in ECM.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Dong Zhu, Yaowu Zhou, Ronghui Zhang & Peng Qin

Authors
  1. Dong Zhu
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  2. Yaowu Zhou
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  3. Ronghui Zhang
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  4. Peng Qin
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Correspondence to Dong Zhu.

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Zhu, D., Zhou, Y., Zhang, R. et al. Investigation of leveling ability improvement in pulse electrochemical machining for aero structural components. Int J Adv Manuf Technol 86, 1723–1732 (2016). https://doi.org/10.1007/s00170-015-8295-4

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  • DOI: https://doi.org/10.1007/s00170-015-8295-4

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