SUNConferences, COMA '13

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Study of Pulse Electrochemical Machining Characteristics of Spheroidal Cast Iron Using Sodium Nitrate Electrolyte
Olivier Weber, Dirk Bähre, Andreas Rebschläger

Last modified: 2013-08-20


Different applications require the positioning of complex geometric contours with high precision and high surface quality demands in work pieces made of cast iron. Valve seats in pump bodies, e.g., are required for the high pressure fuel injection and other hydraulic applications. The electrochemical machining is especially suitable for the very precise production of such elements in series manufacturing. During this process, the negative structure of an electrode is copied to the workpiece without sub surface damages. An adequate knowledge of the machining performance is required to plan the process according to the material properties and to effectuate surface qualities suitable for application. In this contribution, the potential of Pulse Electrochemical Machining (PECM) for the machining of cast iron is investigated with regard to the machining performance during electrolysis with sodium nitrate as electrolyte and stainless steel as cathode. Therefore the material removal characteristics of cast iron with PECM are determined by performing systematic design of experiments techniques applying an industrial PECM machine system (PEMCenter8000) to fulfil the effective utilization of the process and minimize the number of trials. An analysis of the precision of the manufactured geometries and the possibility of generating defined surface qualities are contents of this study. Suggestions for the process design are deduced from these results and a concept for the future modeling is presented.

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