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Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining

Received: 6 August 2018     Accepted: 17 August 2018     Published: 13 September 2018
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Abstract

The non-traditional method used in this work was an electrochemical machining. The experimental work includes designing of machining cell, preparing of fluid solution, selecting the work piece and designing of test rig. The aim of this paper was obtain the gap profile which based on the deviation with respect to equilibrium gap width, also, the electrolyte conductivity deviation with respect to inlet electrolyte conductivity along flow path with the effect electrolyte temperature was obtained for the machining cell. A particular machining cell of two dimensions of (30 mm) width and (50 mm) length, with two dimension turbulent flow for an electrolyte in gap has been selected. For this machining cell, an electrolyte solution (10% w/w NaCl) and the work piece (En8 mild steel) are used. The influence of various parameters, such as supply voltage(12 to 18 volt), tool federate(0.35 to 1.65 mm/min), electrolyte flow rate(5 to 30 lit/min), temperature (40°C) and back pressure (0 to 6 bar) on the gap width and electrolyte conductivity profiles along flow path of the machining cell. The inlet operating parameters for the machining cell were selected within the range of industrially realistic machining circumstances. The optimal control on flow rate and temperature of a electrolyte which refers to gap width without deviation are observed experimentally.

Published in Machine Learning Research (Volume 3, Issue 2)
DOI 10.11648/j.mlr.20180302.12
Page(s) 18-27
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2018. Published by Science Publishing Group

Keywords

Electrochemical Machining, Gap Width, Electrolyte Flow Rate and Temperature, Electrolyte Conductivity, Control

References
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[2] M. M. Lohrengel, K. P. Rataj and T. Munninghoff, “Electrochemical Machining—Mechanisms of Anodic Dissolution”, Electrochimica Acta, Vol. 201, pp. 348-353, 2016.
[3] K. P. Rajurkar and D. Zhu, “Improvement of Electrochemical Machining Accuracy by Using Orbital Electrode Movement”, CIRP Annals - Manufacturing Technology, Vol. 48, Iss. 1, pp. 139-142, 1999.
[4] Sadineni Rama Rao and G. Padmanabhan, “Linear Modeling of the Electrochemical Machining Process Using Full Factorial Design of Experiments”, Journal of Advanced Mechanical Engineering, Vol. 1, pp. 13-23, 2013.
[5] R. Thanigaivelan and Ramanathan Arunachalam, “Optimization of Process Parameters on Machining Rate and Overcut in Electrochemical Micromachining Using Grey Relational Analysis”, Journal of Scientific and Industrial Research, Vol. 72. Iss. 1, 2013.
[6] N. K. Jain and V. K. Jain, “OPTIMIZATION OF ELECTRO-CHEMICAL MACHINING PROCESS PARAMETERS USING GENETIC ALGORITHMS”, Machining Science and Technology An International Journal, Vol. 11, Iss. 2, pp. 235-258, 2007.
[7] R. Venkata Rao and V. D. Kalyankar, “Optimization of modern machining processes using advanced optimization techniques: a review”, The International Journal of Advanced Manufacturing Technology, Vol. 73, Iss. 5–8, pp. 1159–1188, 2014.
[8] B. R. Sarkar, B. Doloi and B. Bhattacharyya, “Parametric analysis on electrochemical discharge machining of silicon nitride ceramics”, The International Journal of Advanced Manufacturing Technology, Vol. 28, Iss. 9–10, pp 873–881, 2006.
[9] C. SENTHILKUMAR, G. GANESAN and R. KARTHIKEYAN, “Parametric optimization of electrochemical machining of Al/15% SiCp composites using NSGA-II”, Transactions of Nonferrous Metals Society of China, Vol. 21, Iss. 10, pp. 2294-2300, 2011.
[10] Rajarshi Mukherjee and Shankar Chakraborty, “Selection of The Optimal Electrochemical Machining Process Parameters Using Biogeography-Based Optimization Algorithm”, The International Journal of Advanced Manufacturing Technology,, Vol. 64, Iss. 5–8, pp 781–791, 2013.
[11] Hansong Li, Chuanping Gao, Guoqian Wang, Ningsong Qu, and Di Zhu, “A Study of Electrochemical Machining of Ti-6Al-4V in NaNO3 solution”, Scientific Reports | 6:35013 | DOI: 10.1038/srep35013, 2016.
[12] Yu Tang and Zhengyang Xu, “The Electrochemical Dissolution Characteristics of GH4169 Nickel Base Super Alloy in the Condition of Electrochemical Machining”, International Journal of Electrochemical Science, Vol. 13, pp. 1105 – 1119, 2018.
[13] Jia Liua, Di Zhua, Long Zhaoa and Zhengyang Xu, “Experimental Investigation on Electrochemical Machining of γ-TiAl Intermetallic”, Procedia CIRP, Vol. 35, pp. 20 – 24, 2015.
[14] S. Madhankumar, Dr. K. Manonmani, Dr. S. Periyasamy, S. Rajesh and S. Kannaki, “Experimental Study of Effect of Parameters on Material Removal Rate for Electrochemical Machining of Aluminium Matrix Composite”, International Journal of Creative Research Thoughts (IJCRT), Vol. 5, Iss. 4, 2017.
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  • APA Style

    Raad Muzahem Fenjan. (2018). Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining. Machine Learning Research, 3(2), 18-27. https://doi.org/10.11648/j.mlr.20180302.12

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    ACS Style

    Raad Muzahem Fenjan. Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining. Mach. Learn. Res. 2018, 3(2), 18-27. doi: 10.11648/j.mlr.20180302.12

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    AMA Style

    Raad Muzahem Fenjan. Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining. Mach Learn Res. 2018;3(2):18-27. doi: 10.11648/j.mlr.20180302.12

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  • @article{10.11648/j.mlr.20180302.12,
      author = {Raad Muzahem Fenjan},
      title = {Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining},
      journal = {Machine Learning Research},
      volume = {3},
      number = {2},
      pages = {18-27},
      doi = {10.11648/j.mlr.20180302.12},
      url = {https://doi.org/10.11648/j.mlr.20180302.12},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.mlr.20180302.12},
      abstract = {The non-traditional method used in this work was an electrochemical machining. The experimental work includes designing of machining cell, preparing of fluid solution, selecting the work piece and designing of test rig. The aim of this paper was obtain the gap profile which based on the deviation with respect to equilibrium gap width, also, the electrolyte conductivity deviation with respect to inlet electrolyte conductivity along flow path with the effect electrolyte temperature was obtained for the machining cell. A particular machining cell of two dimensions of (30 mm) width and (50 mm) length, with two dimension turbulent flow for an electrolyte in gap has been selected. For this machining cell, an electrolyte solution (10% w/w NaCl) and the work piece (En8 mild steel) are used. The influence of various parameters, such as supply voltage(12 to 18 volt), tool federate(0.35 to 1.65 mm/min), electrolyte flow rate(5 to 30 lit/min), temperature (40°C) and back pressure (0 to 6 bar) on the gap width and electrolyte conductivity profiles along flow path of the machining cell. The inlet operating parameters for the machining cell were selected within the range of industrially realistic machining circumstances. The optimal control on flow rate and temperature of a electrolyte which refers to gap width without deviation are observed experimentally.},
     year = {2018}
    }
    

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  • TY  - JOUR
    T1  - Experimental Study of Hydrodynamic Characteristics and Heat Transfer for a Fluid Flow into a Non-Traditional Machining
    AU  - Raad Muzahem Fenjan
    Y1  - 2018/09/13
    PY  - 2018
    N1  - https://doi.org/10.11648/j.mlr.20180302.12
    DO  - 10.11648/j.mlr.20180302.12
    T2  - Machine Learning Research
    JF  - Machine Learning Research
    JO  - Machine Learning Research
    SP  - 18
    EP  - 27
    PB  - Science Publishing Group
    SN  - 2637-5680
    UR  - https://doi.org/10.11648/j.mlr.20180302.12
    AB  - The non-traditional method used in this work was an electrochemical machining. The experimental work includes designing of machining cell, preparing of fluid solution, selecting the work piece and designing of test rig. The aim of this paper was obtain the gap profile which based on the deviation with respect to equilibrium gap width, also, the electrolyte conductivity deviation with respect to inlet electrolyte conductivity along flow path with the effect electrolyte temperature was obtained for the machining cell. A particular machining cell of two dimensions of (30 mm) width and (50 mm) length, with two dimension turbulent flow for an electrolyte in gap has been selected. For this machining cell, an electrolyte solution (10% w/w NaCl) and the work piece (En8 mild steel) are used. The influence of various parameters, such as supply voltage(12 to 18 volt), tool federate(0.35 to 1.65 mm/min), electrolyte flow rate(5 to 30 lit/min), temperature (40°C) and back pressure (0 to 6 bar) on the gap width and electrolyte conductivity profiles along flow path of the machining cell. The inlet operating parameters for the machining cell were selected within the range of industrially realistic machining circumstances. The optimal control on flow rate and temperature of a electrolyte which refers to gap width without deviation are observed experimentally.
    VL  - 3
    IS  - 2
    ER  - 

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Author Information
  • Department of Materials Engineering, Mustansiriyah University, Bagdad, Iraq

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