ABSTRACT

Shaped-Tube Electrolytic Drilling (STED), being an electrochemical-based process, undergoes issues related to machining inaccuracies, e.g., stray cutting and non-uniform dissolution, and they still need attention. Along with other process-related factors, the instantaneous state of the inter-electrode gap (IEG) also affects the process behavior, as it can lead to electrolyte boiling and short-circuiting. Thereby, it is a challenge to have precise control over the state of IEG. While reviewing the available literature and performing experiments, it was observed that the initial temperature of electrolyte may be decisive for the performance of STED process. Therefore, the present research was aimed at investigating the effect, of varying electrolyte entry temperature (EET) along with other factors such as applied voltage, electrolyte concentration, tool feed rate, and electrolyte flow rate, on the average diametral overcut (ADOC), material removal rate (MRR), roundness error, and surface roughness (R_a). The outcomes of using two different EET were compared to elucidate the improvement in the localization of anodic dissolution. The relatively cooler electrolyte (EET 5°C) supplied into the machining zone curtailed extent of stray cutting, and hence, the ADOC, MRR, roundness error, and surface roughness (R_a) were decreased by about 1–21%, 1–5%, 4–19%, and 1–6%, respectively.

摘要

异形管电解钻探（STED）是一种基于电化学的工艺，它遇到了与加工误差有关的问题，例如，杂散切削和不均匀溶解，因此仍然需要注意。电极间间隙（IEG）的瞬时状态与其他与过程相关的因素一起也会影响过程行为，因为它可能导致电解质沸腾和短路。因此，对IEG的状态进行精确控制是一个挑战。在查阅现有文献并进行实验时，观察到电解质的初始温度可能对STED工艺的性能起决定性作用。因此，本研究旨在调查改变电解液进入温度（EET）以及其他因素（例如施加电压，电解液浓度，_a）。比较了使用两种不同EET的结果，以阐明阳极溶出位置的改善。提供给加工区的相对较冷的电解质（EET 5°C）减少了杂散切削的程度，因此，ADOC，MRR，圆度误差和表面粗糙度（R _a）降低了约1–21％，1–分别为5％，4–19％和1–6％。