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Experimental derivation of process input parameters for electrochemical machining with differentially switched currents

Experimentelle Bestimmung von Prozesseingangsgrößen für die elektrochemische Bearbeitung mit differentiell geschalteten Strömen
: Martin, Andre; Petzold, Tom; Hackert-Oschätzchen, Matthias; Meichsner, Gunnar; Schubert, Andreas

Bergs, T.:
14th INSECT 2018, International Symposium on ElectroChemical Machining Technology. Proceedings : Aachen, November 27-28, 2018
Aachen: Apprimus Verlag, 2018
ISBN: 978-3-86359-667-5
ISBN: 3-86359-667-6
International Symposium on ElectroChemical Machining Technology (INSECT) <14, 2018, Aachen>
Fraunhofer IWU ()
ECM; PECM; EC-Präzisionsabtragen

The manufacturing of components with complex internal features, e.g. for automobile industry, aeronautics or medical applications, is a significant challenge. Such components are often machined in temporarily and locally separated stages of production. Due to these separated stages, the form deviations and positioning errors increase, which leads to additional efforts for the quality assurance. The technology that shall be developed within the project Switch ECM is supposed to enable machining of components with differing complex features in one single production stage and shall simultaneously allow for high precision. For this purpose, a multi-cathode system will be developed, in which every single cathode can be switched with specific parameters. The specific switching parameters shall be adjusted according to the requirements of the pre-defined features. For the manufacturing of different pre-defined features with one multi-cathode system the usage of pulsed direct current as well as continuous direct current shall be possible. Hence, removal experiments were carried out on 1.4301 stainless steel using a PEMCenter 8000 with varying feed rates and voltages at a pulsation frequency of 200 Hz. With this comparatively high frequency and a pulse duration of 4 ms pseudo direct current experiments are realized. The results are compared to experiments with a more common pulse frequency of 50 Hz. The mass removal analyses show, in which degree the transferability of experimental results from pulsed current to pseudo direct current or rather direct current is feasible.