The influences of the mask wall angle on the current density distribution,shape of the evolving cavity and machining accuracy were investigated in electrochemical machining(ECM) by mask.A mathematical model was develo...The influences of the mask wall angle on the current density distribution,shape of the evolving cavity and machining accuracy were investigated in electrochemical machining(ECM) by mask.A mathematical model was developed to predict the shape evolution during the ECM by mask.The current density distribution is sensitive to mask wall angle.The evolution of cavity is determined by the current density distribution of evolving workpiece surface.The maximum depth is away from the center of holes machined,which leads to the island appearing at the center of cavity for mask wall angles greater than or equal to 90°(β≥90°).The experimental system was established and the simulation results were experimentally verified.The results indicate that the simulation results of cavity shape are consistent with the actual ones.The experiments also show that the repetition accuracy of matrix-hole for β≥90° is higher than that for β<90°.A hole taper is diminished,and the machining accuracy is improved with the mask wall angle increasing.展开更多
Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simu...Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simulate the electric field in a 75 kA drained aluminum reduction cell. The current distribution and influences of the cathode inclination angle and anode-cathode distance (ACD) were studied. The results show that relatively large horizontal current density appears in the aluminum film, and the maximum value reaches 600 kA/m2. As the cathode inclination angle increases from 2° to 15°, the maximum current density of the metal pad increases by 15%, while the maximum current density of the aluminum-wettable coating layer decreases by 27%. The influence of the ACD on the current distribution is not obvious.展开更多
基金Project(50635040) supported by the National Natural Science Foundation of ChinaProject(2009AA044205) supported by the National High Technology Research and Development ProgramProject(BK2008043) supported by the Jiangsu Provincial Natural Science Foundation,China
文摘The influences of the mask wall angle on the current density distribution,shape of the evolving cavity and machining accuracy were investigated in electrochemical machining(ECM) by mask.A mathematical model was developed to predict the shape evolution during the ECM by mask.The current density distribution is sensitive to mask wall angle.The evolution of cavity is determined by the current density distribution of evolving workpiece surface.The maximum depth is away from the center of holes machined,which leads to the island appearing at the center of cavity for mask wall angles greater than or equal to 90°(β≥90°).The experimental system was established and the simulation results were experimentally verified.The results indicate that the simulation results of cavity shape are consistent with the actual ones.The experiments also show that the repetition accuracy of matrix-hole for β≥90° is higher than that for β<90°.A hole taper is diminished,and the machining accuracy is improved with the mask wall angle increasing.
基金Project(2005CB623703) supported by the National Basic Research Program of China
文摘Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simulate the electric field in a 75 kA drained aluminum reduction cell. The current distribution and influences of the cathode inclination angle and anode-cathode distance (ACD) were studied. The results show that relatively large horizontal current density appears in the aluminum film, and the maximum value reaches 600 kA/m2. As the cathode inclination angle increases from 2° to 15°, the maximum current density of the metal pad increases by 15%, while the maximum current density of the aluminum-wettable coating layer decreases by 27%. The influence of the ACD on the current distribution is not obvious.
