| 研究実績の概要 |
5-axis Jet-ECM setup was developed and the machining experiments of workpieces with freeform surfaces were successfully conducted. The optimal machining conditions, including gap control, jet postures, workpiece geometries and gap conditions etc. for 5-axis Jet-ECM were experimentally investigated. Furthermore, the principle of the current density distribution in uneven Jet-ECM gaps was clarified through both simulation and experimental verification. It is found that in 5-axis Jet-ECM, no precise gap control is required in Jet-ECM by using constant current machining mode. The jet angle relative to the workpiece surface had significant influences on the Jet-ECM results. On the other hand, the jet direction had little influence on Jet-ECM. On the other hand, the performances of Jet-ECM of corners is greatly affected by the corner angles and geometric shapes. The machining depth increased and the machining area became small when the angle or the radius of curvature of the corner was decreased due to significant current concentration at the tip. Multiphysics-coupled simulation of Jet-ECM was conducted. The simulation suggested that the electrolyte flow in the gap was significantly affected by the jet angle. Furthermore, the peak of the normal current density distribution on the workpiece surface was displaced from the jet center by about half of the jet thickness when the jet was angled. Verifying experiments of flat Jet-ECM were conducted and the machining results showed good agreement with the simulation results.
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