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Research Papers

Numerical Simulation and Experimentation on Electrochemical Buffing

[+] Author and Article Information
Piyushkumar B. Tailor

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Powai,
Mumbai 400076, India
e-mail: tailorpb@gmail.com

Amit Agrawal

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Powai,
Mumbai 400076, India
e-mail: amit.agrawal@iitb.ac.in

Suhas S. Joshi

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Powai,
Mumbai 400076, India
e-mail: ssjoshi@iitb.ac.in

1Corresponding author.

Manuscript received August 16, 2015; final manuscript received October 30, 2015; published online January 12, 2016. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 138(6), 061009 (Jan 12, 2016) (11 pages) Paper No: MANU-15-1418; doi: 10.1115/1.4032087 History: Received August 16, 2015; Revised October 30, 2015

The electrochemical buffing (ECB) process primarily works on the principle of preferential dissolution by coupling of electrical, chemical, and mechanical actions. ECB is used to buff clean and hygienic nanoscale surface finish of high-purity components. Despite being well known, the process mechanism has not been discussed adequately in the literature, which makes process control and its use difficult. This work explores the various material removal mechanisms through numerical simulations to better understand and control the ECB process. The numerical results are found to match reasonably well with the experimental data. It is found from the simulation results that the flux of species generated is dominated by current density and interelectrode gap, whereas flow of electrolyte and rotation speed of buff-head primarily influence their migration. The simulation model also infers that convective flux contributes of order of 102 over to diffusion flux in species migration, whereas electrophoretic flux does not have a significant contribution.

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Figures

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Fig. 1

Working principle of ECB

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Fig. 2

Two-dimensional model geometry of ECB

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Fig. 3

Schematic line diagram of parallel plates electrode channel

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Fig. 4

Comparative concentration profile of Na+ species along the cross stream at outlet (id: 1000 mA/cm2, u: 0.01 m/s, and initial concentration: 600 mol/m3)

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Fig. 5

Validation of the model with experimental results

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Fig. 6

Photograph of ECB setup

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Fig. 7

Streamwise variation of flux of various species under different current densities (concentration of electrolyte: 10%, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece and buff-head)

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Fig. 8

Flux of species over cross-stream under different current densities (concentration of electrolyte: 15%, interelectrode gap: 100 μm, flow of electrolyte: 15 LPH, and rotational speed of buff-head: 300 rpm)

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Fig. 9

Streamwise flux generation of species for different concentrations of electrolyte (current density: 4.08 mA/cm2, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece/buff-head)

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Fig. 10

Effect of concentration of electrolyte on ionic conductivity

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Fig. 11

Streamwise flux generation of species for different interelectrode gaps (current density: 4.08 mA/cm2, concentration of electrolyte: 10%, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece /buff-head)

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Fig. 12

Streamwise flux generation of species at different flow rates of electrolyte (current density: 4.08 mA/cm2, concentration of electrolyte: 10%, interelectrode gap: 125 μm, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece/buff-head)

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Fig. 13

Streamwise flux generation of species at different rotational speeds (current density: 4.08 mA/cm2, concentration of electrolyte: 10%, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece/buff-head)

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Fig. 14

Streamwise current density at different rotational speeds (current density: 4.08 mA/cm2, concentration of electrolyte: 10%, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece/buff-head)

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Fig. 15

Streamwise concentration of species near surfaces of electrodes (current density: 5.88 mA/cm2, concentration of electrolyte: 10%, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece/buff-head)

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Fig. 16

Concentration of species over the cross-stream at different radial distances (current density: 2.29 mA/cm2, concentration of electrolyte: 15%, interelectrode gap: 100 μm, flow of electrolyte: 15 LPH, and rotational speed of buff-head: 300 rpm)

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Fig. 17

Streamwise flux generation of species by different mechanisms (concentration of electrolyte: 10%, interelectrode gap: 125 μm, flow of electrolyte: 20 LPH, and rotational speed of buff-head: 600 rpm, at 1 μm from workpiece and buff-head)

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Fig. 18

Comparison of the model prediction with experimental results

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Fig. 19

Micrographs of workpiece surface before and after ECB

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