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1、AcceleratedElectrochemicalMachiningToolDesignCOMSOLConference2017Boston,MA5Oct2017BrianSkinna,TimothyHalla,StephenSnydera,K.P.Rajurkarb,E.J.TayloraaFaradayTechnology,Inc.,Englewood,OH45315bDept.ofMechanical&MaterialsEngineering,UniversityofNebraska–Lincoln,Lincoln,NE68588BrianSkinn@Far

2、adayTechnology.comOutline?ElectrochemicalMachining(ECM)?ECMTests–ApparatusandMethods–ResultsandCharacterization?COMSOL?Modeling–ResultsandComparisontoExperimentCOMSOLConferenceBoston-BSkinn-5Oct20172ElectrochemicalMachiningElectrochemicalMachining–+COMSOLConferenceBoston-BSkinn-5Oct201

3、74ElectrochemicalMachiningKeyadvantages?:oApplicabilitytodifficulttocutmaterials,?Notoolwear/No(thermal/mechanicalsurfacedamage,oHighmaterialremovalrate,oSmoothbrightsurfacefinish,andoProductionofpartswithcomplexgeometry.Keychallenges?:1.Disposalofmachiningproducts?(priorFaraday)2.Elec

4、trolyteprocessing?(priorFaraday)3.Tooldesign?(currentFaraday)4.Machiningaccuracy?(currentFaraday)5.Processmonitoring?(priorsensor/automationadvancements)?K.P.Rajurkar,D.Zhu,J.A.McGeough,J.Kozak,A.DeSilva,“NewDevelopmentsinElectro-ChemicalMachining”AnnalsoftheCIRPVol82(2)1999.COMSOLConf

5、erenceBoston-BSkinn-5Oct20175ECMTestsECMApparatusRodorTubeTool3-DPrintedFlowModule4130SteelFlatPanelECMPartCOMSOLConferenceBoston-BSkinn-5Oct20177ECMExperimentalParametersToolMovementvtoolElectrolyteFlow–ElectrolyteNaCl+VDCorAppliedNaNO3PotentialCOMSOLConferenceBoston-BSkinn-5Oct20178E

6、CMTests–ResultsParameterUnitsTest1Test2Test3Test4Test5Test6Test7Tool–RodRodRodTubeRodRodTubeElectrolyte–NaClNaClNaClNaClNaClNaNO3NaNO3VV551510101010DCvin/min–0.0120.0060.0060.0060.0060.006toolδin0.0500.0500.0750.0750.0750.0750.075oΔtmin204.32020201614PhotoPreliminaryTestMatrixTestsCOMS

7、OLConferenceBoston-BSkinn-5Oct20179ECMTestMatrix–CharacterizationRodToolTubeToolNaClNaNONaClNaNO33?RodTool→FlatBase?NaCl→Wider,FasterECM?TubeTool→MoundedBase?NaNO→Tighter,SlowerECM3?SuboptimalFluidFlow→IrregularEdgesCOMSOLConferenceBoston-BSkinn-5Oct201710COMSOL?ModelingModeling–Eval