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Research Papers

Analysis of Electrolytic Flow Effects in Micro-Electrochemical Grinding

[+] Author and Article Information
Suhas S. Joshi

e-mail: ssjoshi@iitb.ac.in
Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Mumbai 400 076, India

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 17, 2010; final manuscript received December 8, 2012; published online January 24, 2013. Assoc. Editor: Kornel Ehmann.

J. Manuf. Sci. Eng 135(1), 011012 (Jan 24, 2013) (9 pages) Paper No: MANU-10-1147; doi: 10.1115/1.4023266 History: Received May 17, 2010; Revised December 08, 2012

Electrochemical grinding (ECG) at macrolevel and microlevel finds increasing use in medical device manufacturing industry. To enhance application of micro-ECG, a comprehensive study of the role electrolyte flow in the formation of hydroxide layer on a workpiece due to electrochemical dissolution, and its removal due to abrasion by a grinding wheel, and erosion by an electrolyte flow has been conducted. Specifically, this paper presents modeling and experimental analysis of turbulent flow in the interelectrode gap (IEG) in the micro-ECG to predict shear stresses at the workpiece boundary. It was found that the shearing forces on the hydroxide layer increase with an increase in electrolyte flow velocity but are halved when the IEG is doubled. Besides elucidating the process mechanism, the theoretical values of forces and metal removal rate (MRR) have been validated experimentally.

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Figures

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Fig. 1

Contributors to material removal in micro-ECG

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Fig. 2

Grid generation and boundary conditions in computation domain

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Fig. 3

Demonstrating grid independence of typical results

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Fig. 4

Contours showing velocity magnitude and distribution in the interelectrode gap region at grinding wheel speed of 510 rpm and electrolyte flow rate of 2.44 m/s

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Fig. 5

Profile of the electrolyte flow in the interelectrode gap in micro-ECG at wheel speed of 194 rpm for interelectrode gap of 6 μm. Inset table data for interelectrode gap of 15 μm.

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Fig. 6

Typical viscous shear stresses along the wall of the workpiece for wheel speed of 194 rpm and electrolyte flow velocity of 2.44 m/s for interelectrode gap of 6 μm. Inset table data for interelectrode gap of 15 μm.

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Fig. 7

Showing evaluation of shearing forces along the work surface periphery

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Fig. 8

(a) Power available in electrolyte flow (b) geometry of wheel, workpiece, and IEG to obtain contact length (c) shear area considered in IEG and (d) top view of IEG geometry

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Fig. 9

(a) Experimental setup for micro-ECG consisting of Kistler minidynamometer mounted under the work holding spindle and other data acquisition system (b) typical circular microgroove of 878 μm width cut using a Cu bonded PCD grinding wheel of thickness 800 μm

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Fig. 10

Contributors to the total MRR (Theoretical) in micro-ECG including, MRR Erosion, MRR Abrasion and MRR ECM and comparison with the MRR (Experimental)

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