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4. Working gap analysis in electrochemical precision machining of external geometries with ring cathodes

Author

Schaarschmidt, I., Hackert-Oschätzchen, M., Meichsner, G., Steinert, P., Zinecker, M., Schubert, A., and Publica

Abstract

Pulsed electrochemical machining (PECM) with oscillating cathode is a non-conventional manufacturing technology to machine complex precision geometries independent from the mechanical properties of the workpiece material. PECM with oscillating cathode is an advanced development of conventional ECM by applying a pulsed electric current in conjunction with an oscillating movement of the cathode. Result is electrochemical precision machining with a more stable process combined with better accuracy and quality. This work focuses on the analysis of the resulting side working gap in electrochemical precision machining of external geometries by applying PECM. Therefore, the height of a ring cathode was varied to adjust the cathode inner surface. The resulting side working gap was studied through multiscale multiphysics simulation applying COMSOL Multiphysics as well as experiments applying a PEMCenter 8000. As main result, the increase of the resulting side working gap as consequence of an increasing cathode inner surface will be analysed in detail.

Published
2020

5. Knochenmehl induzierte Osseointegration modifizierter, mikrostrukturierter Titan-Implantate im Schafsmodel- Erste experimentelle Ergebnisse

Author

Kemper, M, Kluge, A, Krause, M, Kunert-Keil, C, Meichsner, G, Kant, L, Zahnert, T, and Neudert, M

Subjects
ddc: 610, 610 Medical sciences, Medicine
Abstract

Einleitung: Vorarbeiten zeigten, dass die sichere Prothesenankopplung auf der Stapesfussplatte (FP) und Vermeidung einer Prothesendislokation durch die Ausnutzung des körpereigenen osseoregenerativen Potentials möglich ist. Die Osseointegration von Mittelohrprothesen auf der FP kann mittels[for full text, please go to the a.m. URL], 86. Jahresversammlung der Deutschen Gesellschaft für Hals-Nasen-Ohren-Heilkunde, Kopf- und Hals-Chirurgie

Published
2015
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7. Micro machining with continuous electrolytic free jet

Author

Hackert-Oschätzchen, M., Meichsner, G., Zinecker, M., Martin, A., Schubert, A., and Publica

Subjects
JET-ECM, micro manufacturing, Jet Electrochemical Machining, localized anodic dissolution, micro, continuous electrolytic free jet, jet, COMSOL multiphysic
Abstract

Electrochemical machining (ECM) is a potential procedure for high precision micro manufacturing. Especially the machining of metallic work pieces without any thermal or mechanical impact and the independence from the material's hardness are significant features. In this study, a special procedure for the fabrication of complex microgeometries and microstructured surfaces is investigated. This will be done by help of a continuous electrolytic free jet (Jet Electrochemical Machining-Jet-ECM). Characteristic for this technology is the restriction of the electric current to a limited area by the jet. Thereby, a high localization of the removal area is obtained which can easily be controlled by changing the electric current and the nozzle position. Applying continuous direct current, higher dissolution rates compared to pulsed EC processes are possible. The machining process is at first simulated by help of the finite elements method. Therefore, the commercial simulation sof tware COMSOL Multiphysics was used applying time-dependent calculation rules. Experiments were performed to quantify the Jet-ECM process. By comparing the simulated and the experimental results, a good coincidence has been found. Furthermore, experiments were executed to show the capabilities of possible Jet-ECM applications regarding point erosions, cutting, drilling and milling.

Published
2012

8. Präzise elektrochemische Bearbeitung von pulvermetallurgischen Stählen

Author

Schubert, A., Meichsner, G., Hackert-Oschätzchen, M., Zinecker, M., Edelmann, J., and Publica

Subjects
präzise elektrochemische Bearbeitung, gepulste elektrochemische Bearbeitung, PM-Stahl, pulvermetallurgische Stähle, PECM
Abstract

Es wird eine Untersuchung zum Einsatzpotenzial der gepulsten elektrochemischen Bearbeitung (PECM) für die Formgebung von pulvermetallurgisch hergestellten Stählen (PM-Stähle) vorgestellt. PM-Stähle zeichnen sich insbesondere durch ihre hohe Härte und hohe Verschleißbeständigkeit aus und werden daher als Material für Stanz- und Umformwerkzeuge eingesetzt [1]. Alternativ zu konventionellen Fertigungsverfahren kann die PECM Technologie zur Bearbeitung genutzt werden. Hierfür wurde die Abtragscharakteristik des PECM-Verfahrens für drei unterschiedliche PM-Stähle durch systematische Experimente ermittelt. Eingesetzt wurde eine kommerziell verfügbare Fertigungsanlage vom Typ PEMCenter 8000 (PEMTec, Forbach, Frankreich). Die Bearbeitungsergebnisse wurden anhand von Geometriekennzahlen und Oberflächenmerkmalen bewertet.

Published
2012

20. Micro Machining of Different Steels with Closed Electrolytic Free Jet.

Author

Hackert-Oschätzchen, M., Meichsner, G., Zeidler, H., Zinecker, M., and Schubert, A.

Subjects
*STEEL, *MICROMACHINING, *ELECTROCHEMICAL cutting, *JETS (Fluid dynamics), *MICROFABRICATION, *ELECTRIC currents, *METALWORK, *SURFACE analysis
Abstract

Electrochemical Machining (ECM) with closed electrolytic free jet (Jet-ECM) is an innovative procedure in micro manufacturing technology which is based on anodic dissolution of metallic work pieces. Main advantage of Jet-ECM in comparison to other ECM processes is the restriction of the electric current to a limited area by the jet. Micro structured surfaces and complex three-dimensional micro geometries can be machined by help of different nozzle movements. In this study the Jet Electrochemical Machining is used to generate micro cavities in different steels to investigate the influence of the material properties on the removal process. Current efficiency, machined geometry and surface properties of the processed areas were analyzed and compared. [ABSTRACT FROM AUTHOR]

Published
2011
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21. Micromanufacturing Of Hard To Machine Materials By Physical And Chemical Ablation Processes.

Author

Schubert, A., Edelmann, J., Gross, S., Zeidler, H., Meichsner, G., Hackert, M., Wolf, N., and Schneider, J.

Subjects
MINIATURE electronic equipment, LASER ablation, ELECTRIC metal-cutting, ELECTROCHEMICAL cutting, MICROFLUIDICS, EMBOSSING (Metalwork), TRIBOLOGY, MICROSTRUCTURE, CERAMICS, STEEL
Abstract

Miniaturization leads to high requirements to the applied manufacturing processes especially in respect to the used hard to machine materials and the aims of structure size and geometrical accuracy. Traditional manufacturing processes reach their limits here. One alternative for these provide thermal and chemical ablation processes. These processes are applied for the production of different microstructures in different materials like hardened steel, carbides and ceramics especially for medical engineering and tribological applications. [ABSTRACT FROM AUTHOR]

Published
2011
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29. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

30. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

31. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

32. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

33. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

34. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

35. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

36. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

37. Dissertatio De Margaritis

Author

Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, Oertel, Johann, Zittelin, Joannes Georgius, Gereus, Georgius, Oertel, Philippus, Haas, Gabriel, Zittelin, Johann Georg, Schmid, Johannes, Sebizius, Melchior, Francus, Georgius, Willius, J. V., Artopoeus, Joh. Christophorus, Wieger, Fridericus, Rapp, Jo. Henr., Meyerus, Joh. Fridericus, Kynast, Philippu Ludobiku, Leonhard, Joh. Frideric., Fuchs, Rutilius, Rögnerus, Georg. Ludovic., Boeclerus, Johannes, Rübner, Andreas, Faustius, Johannes, Kämpffer, Joh. Nicolaus, Meichsner, G. W., Saltzmann, Johann Rudolph, and Oertel, Johann

46. High-resolution imaging of ion conductivity of Nafion® membranes with electrochemical atomic force microscopy

Author

Hiesgen, R., Aleksandrova, E., Meichsner, G., Wehl, I., Roduner, E., and Friedrich, K.A.

Subjects
*POLYTEF, *ARTIFICIAL membranes, *ELECTROCHEMICAL analysis, *ELECTRIC conductivity, *ATOMIC force microscopy, *SURFACES (Technology), *MICELLES, *SOLIDIFICATION
Abstract

Abstract: Conductive electrochemical AFM images demonstrating the complex nature and structure of Nafion surface conductivity are presented. Nanoscale regions with high currents determining the overall total membrane current can be distinguished from majority domains with lower currents and non-conductive areas. The different conductive domains form ordered structures and show a specific dynamic behaviour. These observations were compared to the structural and electrical models in the literature. None of the models is able to explain all aspects of the current images. The existence of inverted micelles seems to be quite probable since the formation of agglomerates like chains and larger ordered clusters is clearly visible. This aspect is best described by the model of Schmidt-Rohr and Chen. In addition, the highly dynamic behaviour and distribution of conductive channels of Nafion leading to the formation of new current pathways also indicates the formation of different meso-phases with a high local fluctuation rate. The other discussed models also predict structural features which are in agreement with our observations like the formation of super-structures and agglomeration of fibers. The structural characterisation reflects the situation at or near the membrane surface and might differ from the bulk structure since the surface energy may have a large influence on the formation of structures during the membrane solidification process. The quite large dynamics of conductivity changes of Nafion reflected in the formation of new current pathways even at room temperature leads to the assumption that the internal structure of Nafion is subject to significant changes due to humidity and temperature variations. The local variation of individual structures may reflect the variation of concentration of hydrophilic and hydrophobic groups during membrane solidification. The minimization of surface free energy during a self-assembling process is essential for the formation of different phases and subsequent structures like chains, etc. as well as higher order clustering. [Copyright &y& Elsevier]

Published
2009
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47. Characterization of iron(III) in aqueous and alkaline environments with ab initio and ReaxFF potentials.

Author

Riefer A, Hackert-Oschätzchen M, Plänitz P, and Meichsner G

Abstract

The iron(III) complexes [Fe(H2O)n(OH)m]3-m (n + m = 5, 6, m ≤ 3) and corresponding proton transfer reactions are studied with total energy calculations, the nudged elastic band (NEB) method, and molecular dynamics (MD) simulations using ab initio and a modification of reactive force field potentials, the ReaxFF-AQ potentials, based on the implementation according to Böhm et al. [J. Phys. Chem. C 120, 10849-10856 (2016)]. Applying ab initio potentials, the energies for the reactions [Fe(H2O)n(OH)m]3-m + H2O → [Fe(H2O)n-1(OH)m+1]2-m + H3O+ in a gaseous environment are in good agreement with comparable theoretical results. In an aqueous (aq) or alkaline environment, with the aid of NEB computations, respective minimum energy paths with energy barriers of up to 14.6 kcal/mol and a collective transfer of protons are modeled. Within MD simulations at room temperature, a permanent transfer of protons around the iron(III) ion is observed. The information gained concerning the geometrical and energetic properties of water and the [Fe(H2O)n(OH)m]3-m complexes from the ab initio computations has been used as reference data to optimize parameters for the O-H-Fe interaction within the ReaxFF-AQ approach. For the optimized ReaxFF-AQ parameter set, the statistical properties of the basic water model, such as the radial distribution functions and the proton hopping functions, are evaluated. For the [Fe(H2O)n(OH)m]3-m complexes, it was found that while geometrical and energetic properties are in good agreement with the ab initio data for gaseous environment, the statistical properties as obtained from the MD simulations are only partly in accordance with the ab initio results for the iron(III) complexes in aqueous or alkaline environments., (© 2024 Author(s). All article content, except where otherwise noted, is licensed under a Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).)

Published
2024
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48. Process Control in Jet Electrochemical Machining of Stainless Steel through Inline Metrology of Current Density.

Author

Yahyavi Zanjani M, Hackert-Oschätzchen M, Martin A, Meichsner G, Edelmann J, and Schubert A

Abstract

Jet electrochemical machining (Jet-ECM) is a flexible method for machining complex microstructures in high-strength and hard-to-machine materials. Contrary to mechanical machining, in Jet-ECM there is no mechanical contact between tool and workpiece. This enables Jet-ECM, like other electrochemical machining processes, to realize surface layers free of mechanical residual stresses, cracks, and thermal distortions. Besides, it causes no burrs and offers long tool life. This paper presents selected features of Jet-ECM, with special focus on the analysis of the current density during the machining of single grooves in stainless steel EN 1.4301. Especially, the development of the current density resulting from machining grooves intersecting previous machining steps was monitored in order to derive systematic influences. The resulting removal geometry is analyzed by measuring the depth and the roughness of the machined grooves. The correlation between the measured product features and the monitored current density is investigated. This correlation shows that grooves with the desired depth and surface roughness can be machined by controlling current density through the adjustment of process parameters. On the other hand, current density is sensitive to the changes of working gap. As a consequence of the changes of workpiece form and size for the grooves intersecting premachined grooves as well as the grooves with a lateral gap, working gap, and current density change. By analyzing monitoring data and removal geometry results, the suitability of current density inline monitoring to enable process control is shown, especially with regards to manufacture products that should comply with tight predefined specifications.

Published
2019
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49. Process Understanding of Plasma Electrolytic Polishing through Multiphysics Simulation and Inline Metrology.

Author

Danilov I, Hackert-Oschätzchen M, Zinecker M, Meichsner G, Edelmann J, and Schubert A

Abstract

Currently, the demand for surface treatment methods like plasma electrolytic polishing (PeP)-a special case of electrochemical machining-is increasing. This paper provides a literature review on the fundamental mechanisms of the plasma electrolytic polishing process and discusses simulated and experimental results. The simulation shows and describes a modelling approach of the polishing effect during the PeP process. Based on the simulation results, it can be assumed that PeP can be simulated as an electrochemical machining process and that the simulation can be used for roughness and processing time predictions. The simulation results exhibit correlations with the experimentally-achieved approximation for roughness decrease. The experimental part demonstrates the results of the PeP processing for different times. The results for different types of roughness show that roughness decreases exponentially. Additionally, a current efficiency calculation was made. Based on the experimental results, it can be assumed that PeP is a special electrochemical machining process with low passivation., Competing Interests: The authors declare no conflict of interest.

Published
2019
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