Precision improvements in ECM via tool insert development by 3D printing

Scott Sneddon, Anjali K.M. De Silva*, Ares A. Gomez-Gallegos, Prabodha Jayasinghe

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

2 Citations (Scopus)
65 Downloads (Pure)

Abstract

This paper reports the tool developments for electrochemical machining (ECM) of precision parts for automotive industry using polymer 3D printed inserts. The role of these inserts is to control the fluid flow in the inter-electrode gap as well as to prevent stray machining by providing insulation. Initial trial and error machining experiments with various tool insert shapes yielded positive outcomes in terms of controlling stray dissolution. It became evident that by 3D printing the entire machining cell structure with integrated, exchangeable tool inserts, all made from polymer, can further enhance the ECM process. This cell-insert assembly enabled better control of the electrochemical dissolution process and allowed for less restrictive flow of the electrolyte, reducing turbulence in the inter-electrode gap. Thus, by improving the electrolyte flow conditions and providing appropriate insulation to prevent stray machining, the 3D printed cell/insert assemblies enabled ECM to achieve a shaped profile of an auto engine component to required tolerances.

Original languageEnglish
Title of host publication21st CIRP CONFERENCE ON ELECTRO PHYSICAL AND CHEMICAL MACHINING
EditorsKonrad Wegener, Stefan Fabbro, Paulo Matheus Borges
PublisherElsevier B.V.
Pages459-464
Number of pages6
Volume113
ISBN (Print)9781713862895
DOIs
Publication statusPublished - 2022
Event21st Cirp Conference on Electro Physical and Chemical Machining 2022 - Zurich, Switzerland
Duration: 14 Jun 202216 Jun 2022
https://www.swissphotonics.net/home?event_id=4104 (Link to conference website)

Publication series

NameProcedia CIRP
PublisherElsevier B.V.
ISSN (Print)2212-8271

Conference

Conference21st Cirp Conference on Electro Physical and Chemical Machining 2022
Abbreviated titleCirp ISEM XXI
Country/TerritorySwitzerland
CityZurich
Period14/06/2216/06/22
Internet address

Keywords

  • 3D printing
  • dissolution control
  • ECM

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering

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