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Abstract

The machining technology of electrochemical micromachining with ultra short voltage pulses (μPECM) is based on the already well-established fundamentals of common electrochemical manufacturing technologies. The enormous advantage of the highest manufacturing precision underlies the fact of the extremely small working gaps achievable through ultra short voltage pulses in nanosecond duration. This describes the main difference with common electrochemical technologies. With the theoretical resolution of 10 nm, this technology enables high precision manufacturing.

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Authors and Affiliations

Richard Zemann
Friedrich Bleicher
Reinhard Zisser-Pfeifer
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Abstract

In the paper, the authors present a mathematical and numerical model of two-dimensional electrolyte flow in an interelectrode gap. Computer software for flow simulation with the possibility of visualization of distribution of physical conditions during process has been elaborated. The proposed mathematical model of electrolyte flow was verified experimentally by comparing real profiles of machined surface with profiles obtained in computer simulation. For this purpose there was examined a case of machining with a vibrating electrode and without vibrations.
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Authors and Affiliations

Lucjan Dąbrowski
Tomasz Paczkowski
ORCID: ORCID
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Abstract

This paper presents an analysis of the impact of inertial forces of the electrolyte flow in an interelectrode gap on the effects of ECM process of curvilinear rotary surfaces. Considering a laminar flow in the interelectrode gap, the equations of the flow of the mixture of electrolyte and hydrogen in the curvilinear orthogonal coordinate system have been defined. Two classes of equations of motion have been formulated, which differ in the estimates referred to the components of velocity and pressure, and which were analytically solved using the method of perturbation.
Using the machined surface shape evolution equation, the energy equation, and the analytical solutions for velocity and pressure, the ECM-characteristic distributions have been determined: of mean velocity, pressure, mean temperature, current density, gas phase concentration, the gap height after the set machining time for the case when there is no influence of inertial forces, the effect of centrifugal forces and, at the same time, centrifugal and longitudinal inertial forces.
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Bibliography

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Authors and Affiliations

Jerzy Sawicki
1
ORCID: ORCID
Tomasz Paczkowski
2
ORCID: ORCID
Jarosław Zdrojewski
3
ORCID: ORCID

  1. Department of Mechanics and Computer Methods, Bydgoszcz University of Science and Technology, Bydgoszcz, Poland
  2. Department of Manufacturing Techniques, Bydgoszcz University of Science and Technology, Bydgoszcz, Poland
  3. Department of Digital Technology, Bydgoszcz University of Science and Technology, Bydgoszcz, Poland

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