Sage Journals: Discover world-class research

Abstract

Ribbed holes can serve to increase the efficiency of the heat exchangers and improve the performance of industrial equipment. Increasing demand for small ribbed holes is a key driver in manufacturing technology research. Electrochemical machining has been shown to be a promising method for this. In this paper, an intermittent low-frequency vibration tool is used to demonstrate significant improvement to the geometry of internal ribbed holes. The process stability, material removal rates, and uniformity of features along the flow direction are improved. Firstly, a 3D model of the flow field within the interelectrode gap was developed to calculate and governing flow regime in the interelectrode gap. The simulation demonstrated that the fluid velocity fluctuates periodically and this enhances electrolyte flushing in the interelectrode gap during the machining process. Then, experimental tests for the manufacture of spiral ribs on small holes (Ø1.5 mm and 20–40 mm depth) are also demonstrated with accompanying variation of the tool vibration amplitude and frequency, respectively. Results show that groove depth was most greatly influenced by the vibration amplitude and that better uniformity could be obtained at higher vibration frequencies. The groove depth increased by 15% over nonvibrating control tests with enhanced uniformity.

Keywords

Helical internal hole electrochemical machining intermittent vibration fluctuation uniformity groove depth

Get full access to this article

View all access options for this article.

References

Schiele

Wittig

. Gas turbine heat transfer: Past and future challenges. ASME J Propul Power 2000; 16: 583–589.

Hasanpour

Farhadi

Sedighi

. Experimental heat transfer and pressure drop study on typical, perforated, V-cut and U-cut twisted tapes in a helically corrugated heat exchanger. Int Commun Heat Mass Transfer 2016; 71: 126–136.

Krückels J, Arzel T, Kingston, TR and Schnieder M. Turbine Blade Thermal Design Process Enhancements for Increased Firing Temperatures and Reduced Coolant Flow. ASME Turbo Expo 2007; Power for Land, Sea, and Air; Montreal, Canada, 4: Parts A and B.

Ridouane

Campo

. Heat transfer and pressure drop characteristics of laminar air flows moving in a parallel-plate channel with transverse hemi-cylindrical cavities. Int J Heat Mass Transfer 2007; 50: 3913–3924.

Cui

Xin

. Experiments on heat transfer enhancement in 3D inner finned helical pipe. Nucl Power Eng 2005; 26: 6–11.

Jiang

Zhang

Zhao

. Investigation of interface compatibility during ball spinning of composite tube of copper and aluminum. Int J Adv Manuf Technol 2017; 88: 683–690.

Tang

Chi

Chen

J Ch

et al.

Experimental study of oil-filled high-speed spin forming micro-groove fin-inside tubes. Int J Mach Tools Manuf 2007; 47: 1059–1068.

Jiang

Huang

Tang

. Fabrication and thermal performance of porous crack composite wick flattened heat pipe. Appl Therm Eng 2014; 66: 140–147.

Etsion

Halperin

. A laser surface textured hydrostatic mechanical seal. Tribol Trans 2002; 45: 430–434.

10.

Liu

Zhang

Jiang

. Investigation of pulse electrochemical sawing machining of micro-inner annular groove on metallic tube. Int J Mach Tools Manuf 2016; 102: 22–34.

11.

Tangsri

Norasethasopon

Kazunari

. Fabrication of small size inner spiral ribbed copper tube by fluid mandrel drawing. Int J Adv Manuf Technol 2014; 70: 1923–1930.

12.

Jain

Chavan

Kulkarni

. Analysis of contoured holes produced using STED process. Int J Adv Manuf Technol 2009; 44: 133–148.

13.

Pattavanitch

Hinduja

. Machining of turbulated cooling channel holes in turbine blades. CIRP Ann Manuf Technol 2012; 61: 199–202.

14.

Kim

Chu

. Micro electrochemical machining for complex internal micro features. CIRP Ann Manuf Technol 2009; 58: 181–184.

15.

Wang

Liu

Peng

. Multiphysics research in electrochemical machining of internal spiral hole. Int J Adv Manuf Technol 2014; 74: 749–756.

16.

Natsu

. Proposal of ECM method for holes with complex internal features by controlling conductive area ratio along tool electrode. Precis Eng 2015; 42: 179–186.

17.

Wang

Zhang

et al.

Deep micro-hole fabrication in EMM on stainless steel using disk micro-tool assisted by ultrasonic vibration. J Mater Process Technol 2016; 229: 475–483.

18.

Munda

Malapati

Bhattacharyya

. Control of microspark and stray-current effect during EMM process. J Mater Process Technol 2007; 194: 151–158.

19.

Yang

Park

Chu

. Micro ECM with ultrasonic vibrations using a semi-cylindrical tool. Int J Precis Eng Manuf 2009; 10: 5–10.

20.

Ebeid

Hewidy

El-Taweel

et al.

Towards higher accuracy for ECM hybridized with low-frequency vibrations using the response surface methodology. J Mater Process Technol 2004; 149: 432–438.

21.

Hewidy

Ebeid

El-Taweel

et al.

Modelling the performance of ECM assisted by low frequency vibrations. J Mater Process Technol 2007; 189: 466–472.

22.

Lei

et al.

Vibration-assisted micro-ECM combined with polishing to machine 3D microcavities by using an electrolyte with suspended B4C particles. J Mater Process Technol 2018; 255: 275–284.

23.

Fang

Zhang

et al.

Effects of pulsating electrolyte flow in electrochemical machining. J Mater Process Technol 2014; 214: 36–43.

Effects of tool intermittent vibration on helical internal hole processing in electrochemical machining

Abstract

Keywords

Get full access to this article

References