The inter-electrode gap(IEG) is an essential parameter for the anode shaping process in electrochemical machining(ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of...The inter-electrode gap(IEG) is an essential parameter for the anode shaping process in electrochemical machining(ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of an oval anode workpiece in counter-rotating ECM(CRECM)is investigated. The variation of the minimum IEG is analyzed theoretically, and the results indicate that rather than reaching equilibrium, the minimum IEG in CRECM expands constantly when a constant feed speed is used for the cathode tool. This IEG expansion leads to a poor localization effect and has an adverse influence on the roundness of the machined workpiece. To maintain a small constant IEG in CRECM, a variable feed speed is used for the cathode based on a fitted equation. The theoretical results show that the minimum IEG can be controlled at a small value by using an accelerated feed speed. Experiments have been conducted using a specific experimental apparatus in which the cathode tool is designed as a combined structure of two sectors and a thin sheet. By detecting the machining currents flowing through the minimum IEG, how the latter varies is obtained indirectly. The results indicate that using an accelerated feed speed is effective for controlling the IEG, thereby improving the roundness of the machined workpiece.展开更多
The effects of lntcr-ckxttxxk insertion on the performance of a hollow--electrode plasma torch have been investigated by numerical analysis.Simulation results revealed that when inter-dcctrodes arc inserted,the arc vo...The effects of lntcr-ckxttxxk insertion on the performance of a hollow--electrode plasma torch have been investigated by numerical analysis.Simulation results revealed that when inter-dcctrodes arc inserted,the arc voltages and plasma powers increase due to the increase in the arc length.In addition,it was predicted that thermal efficiency can be improved with the increase in plasma power by injecting plasma gases through the gaps between inter-electrodes.These unique effects of inter-electrode insertion arc a result of the plasma temperatures adjusting themselves to increase arc voltages when the arc column is contracted radially by increasing gas-flow rate or decreasing inter-electrcxk diameter.展开更多
In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpi...In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.展开更多
The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining （HGPECM） is mainly discussed. The auto-regressive（AR） model of group pulse current flowing acros...The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining （HGPECM） is mainly discussed. The auto-regressive（AR） model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, i.e. the white noise response of the Green＇s function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum（CPS）, to the current signals related to the different inter-electrode gap size in the range of 0～5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.展开更多
The multi-channel discharge phenomenon for super-high-thickness(more than 1000 mm)cutting is studied in high-speed wire electrical discharge machining(HS-WEDM).In super-high-thickness cutting,the length of the wire el...The multi-channel discharge phenomenon for super-high-thickness(more than 1000 mm)cutting is studied in high-speed wire electrical discharge machining(HS-WEDM).In super-high-thickness cutting,the length of the wire electrode with a poor conductor is longer in the machining area,so the resistance of wire electrode cannot be ignored.It is found that the main reason for the formation of multi-channel discharge is that there is a high voltage between electrodes after dielectric breakdown due to the resistance characteristics of the wire electrode.When the conventional discharge circuit is used for machining,the voltage between electrodes in the middle of the workpiece is much higher than that at the upper and lower ends,which is easier to generate multi-channel discharge.Multi-channel discharge has the characteristic of dispersing discharge energy,which results in inhomogeneous surface roughness on the whole section of the workpiece.To improve the distribution characteristics of the inter-electrode voltage after dielectric breakdown,a novel discharge circuit is proposed,which gradually increases the inter-electrode voltage of discharge points distributed along the thickness direction of the workpiece,and significantly improves the formation probability of multi-channel discharge on the whole cutting surface.A super-high-thickness workpiece with a thickness of 1000 mm is used for continuous cutting.The cutting speed of the two types of discharge circuit is basically the same.But the surface roughness machined by the rear-end parallel circuit is reduced by 15.8%,and the surface homogeneity is greatly improved.展开更多
The architectural design of electrodes offers new opportunities for next-generation electrochemical energy storage devices(EESDs)by increasing surface area,thickness,and active materials mass loading while maintaining...The architectural design of electrodes offers new opportunities for next-generation electrochemical energy storage devices(EESDs)by increasing surface area,thickness,and active materials mass loading while maintaining good ion diffusion through optimized electrode tortuosity.However,conventional thick electrodes increase ion diffusion length and cause larger ion concentration gradients,limiting reaction kinetics.We demonstrate a strategy for building interpenetrated structures that shortens ion diffusion length and reduces ion concentration inhomogeneity.This free-standing device structure also avoids short-circuiting without needing a separator.The feature size and number of interpenetrated units can be adjusted during printing to balance surface area and ion diffusion.Starting with a 3D-printed interpenetrated polymer substrate,we metallize it to make it conductive.This substrate has two individually addressable electrodes,allowing selective electrodeposition of energy storage materials.Using a Zn//MnO_(2)battery as a model system,the interpenetrated device outperforms conventional separate electrode configurations,improving volumetric energy density by 221%and exhibiting a higher capacity retention rate of 49%compared to 35%at temperatures from 20 to 0℃.Our study introduces a new EESD architecture applicable to Li-ion,Na-ion batteries,supercapacitors,etc.展开更多
基金supported by the National Natural Science Foundation of China (51535006, 51805259)Natural Science Foundation of Jiangsu Province of China (BK20180431)+2 种基金Fundamental Research Funds for the Central Universities of China (3082018NP2018406)Young Elite Scientists Sponsorship Program by CAST of ChinaJiangsu Key Laboratory of Precision and Micro-Manufacturing Technology of China
文摘The inter-electrode gap(IEG) is an essential parameter for the anode shaping process in electrochemical machining(ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of an oval anode workpiece in counter-rotating ECM(CRECM)is investigated. The variation of the minimum IEG is analyzed theoretically, and the results indicate that rather than reaching equilibrium, the minimum IEG in CRECM expands constantly when a constant feed speed is used for the cathode tool. This IEG expansion leads to a poor localization effect and has an adverse influence on the roundness of the machined workpiece. To maintain a small constant IEG in CRECM, a variable feed speed is used for the cathode based on a fitted equation. The theoretical results show that the minimum IEG can be controlled at a small value by using an accelerated feed speed. Experiments have been conducted using a specific experimental apparatus in which the cathode tool is designed as a combined structure of two sectors and a thin sheet. By detecting the machining currents flowing through the minimum IEG, how the latter varies is obtained indirectly. The results indicate that using an accelerated feed speed is effective for controlling the IEG, thereby improving the roundness of the machined workpiece.
文摘The effects of lntcr-ckxttxxk insertion on the performance of a hollow--electrode plasma torch have been investigated by numerical analysis.Simulation results revealed that when inter-dcctrodes arc inserted,the arc voltages and plasma powers increase due to the increase in the arc length.In addition,it was predicted that thermal efficiency can be improved with the increase in plasma power by injecting plasma gases through the gaps between inter-electrodes.These unique effects of inter-electrode insertion arc a result of the plasma temperatures adjusting themselves to increase arc voltages when the arc column is contracted radially by increasing gas-flow rate or decreasing inter-electrcxk diameter.
基金supported by the Program for New Century Excellent Talents in University of China(NCET-10-0074)
文摘In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.
基金This project is supported by the 10th Five-year Plan Pre-research Project Foundation of China Weapon Industry Company, China(No.42001080701).
文摘The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining （HGPECM） is mainly discussed. The auto-regressive（AR） model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, i.e. the white noise response of the Green＇s function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum（CPS）, to the current signals related to the different inter-electrode gap size in the range of 0～5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.
基金supported by the National Natural Science Foundation of China(No.51975290)。
文摘The multi-channel discharge phenomenon for super-high-thickness(more than 1000 mm)cutting is studied in high-speed wire electrical discharge machining(HS-WEDM).In super-high-thickness cutting,the length of the wire electrode with a poor conductor is longer in the machining area,so the resistance of wire electrode cannot be ignored.It is found that the main reason for the formation of multi-channel discharge is that there is a high voltage between electrodes after dielectric breakdown due to the resistance characteristics of the wire electrode.When the conventional discharge circuit is used for machining,the voltage between electrodes in the middle of the workpiece is much higher than that at the upper and lower ends,which is easier to generate multi-channel discharge.Multi-channel discharge has the characteristic of dispersing discharge energy,which results in inhomogeneous surface roughness on the whole section of the workpiece.To improve the distribution characteristics of the inter-electrode voltage after dielectric breakdown,a novel discharge circuit is proposed,which gradually increases the inter-electrode voltage of discharge points distributed along the thickness direction of the workpiece,and significantly improves the formation probability of multi-channel discharge on the whole cutting surface.A super-high-thickness workpiece with a thickness of 1000 mm is used for continuous cutting.The cutting speed of the two types of discharge circuit is basically the same.But the surface roughness machined by the rear-end parallel circuit is reduced by 15.8%,and the surface homogeneity is greatly improved.
基金financial support from the Center for Coastal Climate Resilience of the University of California,Santa Cruz(UCSC)This work was performed under the auspices of the US Department of Energy by Lawrence Livermore National Laboratory under Contract No.DE-AC52-07NA27344 and supported by Laboratory Directed Research and Development award 23-SI-002.IM release number:LLNL-JRNL-862347。
文摘The architectural design of electrodes offers new opportunities for next-generation electrochemical energy storage devices(EESDs)by increasing surface area,thickness,and active materials mass loading while maintaining good ion diffusion through optimized electrode tortuosity.However,conventional thick electrodes increase ion diffusion length and cause larger ion concentration gradients,limiting reaction kinetics.We demonstrate a strategy for building interpenetrated structures that shortens ion diffusion length and reduces ion concentration inhomogeneity.This free-standing device structure also avoids short-circuiting without needing a separator.The feature size and number of interpenetrated units can be adjusted during printing to balance surface area and ion diffusion.Starting with a 3D-printed interpenetrated polymer substrate,we metallize it to make it conductive.This substrate has two individually addressable electrodes,allowing selective electrodeposition of energy storage materials.Using a Zn//MnO_(2)battery as a model system,the interpenetrated device outperforms conventional separate electrode configurations,improving volumetric energy density by 221%and exhibiting a higher capacity retention rate of 49%compared to 35%at temperatures from 20 to 0℃.Our study introduces a new EESD architecture applicable to Li-ion,Na-ion batteries,supercapacitors,etc.
