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Analysis of strategies for gap control in jet electrochemical machining

Analyse von Strategien zur Arbeitsspaltregelung bei der elektrochemischen Bearbeitung mit Jet-ECM
: Hackert-Oschätzchen, Matthias; Martin, Andre; Meichsner, Gunnar; Schubert, Andreas

Leach, R. ; European Society for Precision Engineering and Nanotechnology -EUSPEN-:
14th International Conference & Exhibition of the European Society of Precision Engineering and Nanotechnology 2014 : 2nd June-6th June 2014, Dubrovnik, Croatia; EUSPEN 2014
Bedford: Euspen, 2014
ISBN: 978-0-9566790-3-1
European Society for Precision Engineering and Nanotechnology (EUSPEN International Conference) <14, 2014, Dubrovnik>
Conference Paper
Fraunhofer IWU ()
ECM; anodic dissolution; JET-ECM; gap control

Electrochemical Machining (ECM) is a promising micro-production technique for the creation of complex and highly accurate three-dimensional geometries in electrically conductive materials. As the electrochemical dissolution behavior is independent from the material’s mechanical characteristics like hardness and ductility, ECM is an alternative processing technique to create micro-structures even in mechanically hard to machine alloys.
The basic principle of ECM is the anodic dissolution of work piece material by electric charge transport. As a special procedure electrochemical machining with continuous electrolytic free jet (Jet-ECM) offers the possibility to machine work pieces at extremely high current densities up to 1000 A/cm² [1,2]. In Jet-ECM the electrolyte is pumped continuously through a micro nozzle and ejected with an average speed of approximately 20 m/s perpendicularly to the work piece surface. Thus, a free jet is formed on the surrounding atmospheric air, which leads to a high localization of the current density and therefore to a highly localized machining area around the impinging jet. From the previous work on Jet-ECM the working gap was detected as a significant process variable, which needs an adequate control or adjustment. In this study, an analysis of potential strategies to control this variable is summarized.