Research Papers

Controlled Phase Interactions Between Pulsed Electric Fields, Ultrasonic Motion, and Magnetic Fields in an Anodic Dissolution Cell

[+] Author and Article Information
Curtis Bradley

Integration Engineering Laboratory,
U.S. Army RDECOM-ARDEC Benét Laboratories,
Watervliet, NY 12189
e-mail: curtis.w.bradley6.civ@mail.mil

Johnson Samuel

Department of Mechanical Aerospace
and Nuclear Engineering,
Rensselaer Polytechnic Institute,
Troy, NY 12180
e-mail: samuej2@rpi.edu

1Corresponding author.

Manuscript received March 28, 2017; final manuscript received November 15, 2017; published online February 13, 2018. Assoc. Editor: Y.B. Guo. This work is in part a work of the U.S. Government. ASME disclaims all interest in the U.S. Government's contributions.

J. Manuf. Sci. Eng 140(4), 041010 (Feb 13, 2018) (10 pages) Paper No: MANU-17-1176; doi: 10.1115/1.4038569 History: Received March 28, 2017; Revised November 15, 2017

This paper presents the design of a novel testbed that effectively combines pulsed electric field waveforms, ultrasonic velocity, and magnetic field waveforms in an anodic dissolution electrochemical machining (ECM) cell. The testbed consists of a custom three-dimensional (3D)-printed flow cell that is integrated with (i) a bipolar-pulsed ECM circuit, (ii) an ultrasonic transducer, and (iii) a custom-built high-frequency electromagnet. The driving voltages of the ultrasonic transducer and electromagnet are calibrated to achieve a timed workpiece velocity and magnetic field, respectively, in the machining area. The ECM studies conducted using this testbed reveal that phase-controlled waveform interactions between the three assistances affect both the material removal rate (MRR) and surface roughness (Ra) performance metrics. The triad-assisted ECM case involving phase-specific combinations of all three high-frequency (15.625 kHz) assistance waveforms is found to be capable of achieving a 52% increase in MRR while also simultaneously yielding a 78% improvement in the Ra value over the baseline pulsed-ECM case. This result is encouraging because assisted ECM processes reported in the literature typically improve only one of these performance metrics at the expense of the other. In general, the findings reported in this paper are expected to enable the realization of multifield assisted ECM testbeds using phase-specific input waveforms that change on-the-fly to yield preferential combinations of MRR and surface finish.

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Fig. 1

Multifield-assisted anodic-dissolution electrochemical cell reaction depicting the relevant field vectors and the resulting Lorentz force on a nitrate ion [21]

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Fig. 2

Set diagram of multifield-assisted ECM combinations used as experimental treatments (* indicates a baseline)

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Fig. 3

System block diagram showing the relation between the data, power, and electrolyte flow within the experimental testbed

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Fig. 4

Flow cell design details (a) three-quarter section view, (b) cross section showing electrolyte flow, IEG, and electric field direction, (c) cross section showing ultrasonic velocity and magnetic field directions (note: figure uses left-handed coordinate system)

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Fig. 5

Bipolar pulse ECM circuit utilizing two power supplies

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Fig. 6

Motion tracking of the workpiece corner features showing the mean position point for each frame: (a) base frame A, (b) target frame B, and (c) pseudo-color frame A superimposed on frame B showing displacement

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Fig. 7

Magnetic field map at time intervals between the maximum magnetic field in (a) to minimum in (d) (note: the circular area indicates the machining area)

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Fig. 8

Phase differences between assistance waveforms (Note: PECM current and voltage signals are from experiments, whereas the ultrasonic velocity and magnetic field are simulated signals for illustrative purpose)

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Fig. 9

Coupled dual-assisted ECM performance, (a)–(c) MRR and total anodic charge, (d)–(e) surface roughness in terms of Ra and peak anodic current (note: the scale on the vertical axis is different for each figure for clarity purposes)

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Fig. 10

Four phase differences used in the Ultra–Mag interaction and the resulting estimate of the Lorentz force in the Z-direction r˙×B(r,t) (note: the plot ignores secondary electric fields and is for a positively charged particle close to the ultrasonically vibrating workpiece surface)

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Fig. 11

Performance metrics of 16 triad-assisted ECM experiments showing all phase difference combinations between the waveforms for PECM, ultrasonic velocity, and magnetic fields: (a) MRR and (b) Ra (note: PECM baseline noted on the color bar)

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Fig. 12

Comparison between the assistance cases using the best-performing phasing results: (a) MRR and (b) Ra




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