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Reduplication of precise internal geometries by pulsed electrochemical machining

Replizieren einer Präzisen Innengeometrie durch EC-Präzisionsabtragen
: Meichsner, Gunnar; Petzold, Tom; Hackert-Oschätzchen, Matthias; Edelmann, Jan; Schubert, Andreas; Putz, Matthias; Hahn, Georg

Michaelis, A.; Schneider, M. ; Fraunhofer-Institut für Keramische Technologien und Systeme -IKTS-, Dresden:
13th International Symposium on ElectroChemical Machining Technology, INSECT 2017. Proceedings : November 30-December 1, 2017, Dresden, Germany
Stuttgart: Fraunhofer Verlag, 2017 (Applied electrochemistry in material science Vol. 6)
ISBN: 978-3-8396-1261-3
International Symposium on Electrochemical Machining Technology (INSECT) <13, 2017, Dresden>
Conference Paper
Fraunhofer IWU ()
PECM; electrochemical machining; internal geometries

In the field of spare parts production with small quantities and low stockholding one main method is reduplication of precise internal geometries from a defect part to a spare part. One conventional manufacturing technology for this reduplication is broaching. Since broaching requires extensive and expensive tools especially for small quantities a more resource efficient technology is aspired. Electrochemical machining (ECM) is a potential technology which meets these requirements. ECM transfers a cathode geometry to a workpiece based on anodic dissolution [1]. For this purpose, a specific design for the cathode as well as for the process is required [2]. In the context of process design multiphysics simulation allows a time- and cost-efficient determination of proper process parameters and enables conclusions for the optimization of the cathode geometry [3]. The paper shows an experimental study on the reduplication of precise internal geometries using pulsed electrochemical machining (PECM) applying a two-step approach. Therefore in a first step an initializing workpiece was used to generate a cathode with PECM. This initializing workpiece consists of an internal bore with a diameter of 32 mm. In the second step the reduplication of this internal bore into a workpiece by PECM applying the generated cathode was performed. The workpiece was made of a hardened powder metallurgy steel SAM 10. In the experiments the voltage was varied in a range from 10 V to 17 V and the feed rate was varied from 0,5 mm/s to 1,1 mm/s. By help of the experimental study the influence of both PECM processes on the reduplication result can be determined.