2016 Fiscal Year Research-status Report
5-axis Abrasive-assisted Electrochemical Jet Machining for Surface-processing of Difficult-to-machine Materials
| Project/Area Number |
16K17992
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| Research Institution | The University of Tokyo |
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Principal Investigator |
趙 永華 東京大学, 大学院工学系研究科(工学部), 助教 (90759052)
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| Project Period (FY) |
2016-04-01 – 2018-03-31
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| Keywords | ECM / Electrolyte jet / 5-axis / Corner machining / electrolyte flow field / Simulation |
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| Outline of Annual Research Achievements |
An experimental setup of 5-axis abrasive electrolyte jet machining which included a slurry tank and slurry transport pump was developed and the 5-axis machining characteristics were experimentally investigated based on the setup. On the other hand, the jet shape was simulated and the flow field and electric field were analyzed. The main conclusions are as the following. 1) In the electrolyte jet machining of dimples, the jet angle relative to the workpiece has significant influences on the resulted dimple shapes. With the angled jet, the cross section profile of the resulted dimples shows asymmetry and the deepest point exists where the gap distance is the shortest. 2) Multidiscipline coupled-field analysis of the EJM gap qualitatively indicates that the flow filed in the gap is affected by the jet angle. The current density distribution concentrates at the place where the machining gap is shorter when the jet is angled relative to the workpiece, resulting in a larger material removal. 3) In large-area surface processing, under the same conditions of pick feed, the machined surface flatness error is larger when the jet is angled. 4) EJM can be successfully performed even if the jet is set in a horizontal direction. The jet posture exert no influence on the machining results. 5) The EJM of corners is significantly affected by the corner angles and geometric shapes. The machining depth increases and the machining area decrease when the corner angle and the radius of curvature of the corner becomes smaller.
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| Current Status of Research Progress |
Current Status of Research Progress
2: Research has progressed on the whole more than it was originally planned.
Reason
The main research purpose of the original research plan of 2016, which was the development of the experimental setup of 5-axis abrasive-assisted electrolyte jet machining, has been achieved. In addition, according to the initial research plan, the characterization of 5-axis electrolyte jet machining has been conducted both experimentally and analytically and the research result has been published on a conference.
On the whole, it is considered that the research is progressing as the original plan.
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| Strategy for Future Research Activity |
First, the developed 5-axis EJM machining process will be applied to machine more complex workpieces to investigate its feasibility for practical use. Next, abrasive particles will be added into the electrolyte jet to build abrasive-assisted EJM and experiments on machining of difficult-to-machine materials including titanium alloy, silicon carbide and niobium will be conducted. The effect of adding abrasives into electrolyte jet on removing the oxidation layer will be experimentally clarified. In addition, the optimum machining conditions with regard to the abrasive concentration and jet pressure to achieve the required accuracy will be experimentally investigated. Third, experiments on large area surface finishing by abrasive-assisted EJM will be conducted and the machining performance will be evaluated.
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| Causes of Carryover |
Not applied.
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| Expenditure Plan for Carryover Budget |
Not applied.
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