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Precise machining of complex series production parts

: Brussee, M.; Kraft, M.; Winkler, Sebastian

Bähre, Dirk ; Univ. des Saarlandes, Saarbrücken:
International Symposium on Electrochemical Machining Technology, INSECT 2014. Proceedings : November 13-14, 2014, Saarbrücken, Germany
Zwickau: Verlag Wissenschaftliche Scripten, 2014
ISBN: 978-3-95735-010-7
International Symposium on Electrochemical Machining Technology (INSECT) <10, 2014, Saarbrücken>
Conference Paper
Fraunhofer IWU ()
ECM; PECM; elektrochemisches Abtragen; electrochemical machining

Production of large modern combustion engines requires manufacturing of increasingly complex geometries in combination with difficult-to-machine materials. Precise Electrochemical Machining with oscillating electrode (PECM, PEM) provides an alternative to mechanical machining, offering high technological and economic potential. While tool wear is practically negligible for PECM, complex geometries and high surface qualities can be produced in a low-temperature single-step process with comparably high material removal rates. This paper deals with an advanced manufacturing approach combining a single-axis PECM process with oscillating electrode and a rotating workpiece [13] in order to generate a helical geometry. An experimental setup including a complex motion system was designed and realised. The Nickel-based superalloy Inconel 718 was used for the experiments. A complex geometry has been manufactured using this challenging material, achieving good surface quality and precision. Surface properties were qualified optically and mechanically. Selective material removal of metal phases was observed with SEM and EDX analysis.