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Simulation of the Shape of Micro Geometries Generated with Jet Electrochemical Machining

M. Hackert[1], G. Meichsner[2], and A. Schubert[1,2]
[1]Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany
[2]Fraunhofer Institute of Machine Tools and Forming Technology, Chemnitz, Germany

Electrochemical Machining with a closed electrolytic free jet is a special procedure to generate complex micro structures by help of anodic dissolution. The work piece shape is fabricated by supplying an electrolytic current through an electrolyte jet ejected from a small nozzle. In ... Read More

Transient Simulation of the Removal Process in Plasma Electrolytic Polishing of Stainless Steel

I. Danilov [1], M. Hackert-Oschätzchen [1], I. Schaarschmidt [1], M. Zinecker [1], A. Schubert [1],
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany

Plasma electrolytic polishing (PeP) is an electrochemical method for surface treatment. In detail PeP is a special case of anodic dissolution [1] that unlike electrochemical polishing requires higher voltage and uses environment friendly aqueous solutions of salts. When the process ... Read More

Numerical Investigation of Electrolyte Flow in a Multi-Cathode System for Electrochemical Machining

M. Penzel [1], I. Schaarschmidt [1], M. Hackert-Oschätzchen [1], A. Schubert [1],
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany

Manufacturing and finishing of components with complex internal features is a significant challenge. Industrial sectors like automotive industry, aeronautics or medical technology require these internal features with highest precision and repeatability. Such components are often machined ... Read More

Simulation-based Analysis of a Microstructuring Process for Serrated Surfaces with Higher Friction

I. Schaarschmidt [1], M. Hackert-Oschätzchen [1], G. Meichsner [2], M. Zinecker [1], P. Steinert [1], A. Schubert [1, 2],
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Actual trends in lightweight construction and safety-relevant technologies cause an increasing demand for reliable design of joining connections. Increasing power density and compact design require dimensioning of joints with low safety factors. Thereby additional security measures are ... Read More

Multiscale Model of the PECM with Oscillating Cathode for External Geometries Using a Virtual Switch

I. Schaarschmidt [1], M. Zinecker [1], M. Hackert-Oschätzchen [1], A. Schubert [1], G. Meichsner [2],
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

The machining of hardened steel or powder metallurgical steel, for example to manufacture impact extrusion punches, is a big challenge for conventional machining technology as milling or turning. A non-conventional machining technology is Electrochemical Machining (ECM), which allows ... Read More

Analysis of Mixing Chambers for the Processing of Two-Component Adhesives for Transport Applications

P. Steinert [1], R. Paul [1], I. Schaarschmidt [1], M. Zinecker [1], M. Hackert-Oschätzchen [1], Th. Muschalek [2], J. Esslinger [2], A. Schubert [1]
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany
[2] Rublic+Canzler GmbH, Dresden, Germany

Two-component adhesives are commonly used for sealing and joining in transport applications for mechanically highly stressed connections. At the Chemnitz University of Technology an innovative system technology for the user-friendly, wireless and energy-efficient processing of two ... Read More

Approximation of the Flow Field in Electrochemical Machining Incorporating Pressure Drop Calculation

R. Paul [1], M. Zinecker [1], M. Hackert-Oschätzchen [1], A. Schubert [1],
[1] Professorship Micromanufacturing Technology, Chemnitz University of Technology, Chemnitz, Germany

Electrochemical Machining (ECM) is a non-conventional machining technology which allows for surface structuring and shaping of metallic workpieces with high accuracy and surface quality. The machining principle of ECM is electrolysis. Hence, the mechanical properties of the workpiece ... Read More

Analysis of an Electrochemical Machining Process for Particle Reinforced Aluminum-Matrix Composites

M. Hackert-Oschätzchen [1], N. Lehnert [1], C. Scherf [2], A. Martin [1], M. Penzel [1], A. Schubert [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

At the Technische Universität Chemnitz several academic institutions work on aluminum matrix composites (AMCs) within the Collaborative Research Centre SFB 692 HALS. Besides the development and analysis of these materials one main task is finishing machining of AMCs by an electrochemical ... Read More

Transient Simulation of an Electrochemical Machining Process for Stamping and Extrusion Dies

M. Penzel [1], M. Hackert-Oschätzchen [2], M. Kreißig [1], M. Kowalick [1], M. Zinecker [1], A. Schubert [1], G. Meichsner [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

Precise electrochemical machining (PEM) is a non-conventional machining technology, based on anodic dissolution of metallic work-pieces. In this study an additional extension of the precise electrochemical machining with a precise angle-controlled cylinder positioning is aimed. Due to ... Read More

2D Axisymmetric Simulation of Pulsed Electrochemical Machining (PECM) of Internal Precision Geometries

M. Hackert-Oschätzchen [1], M. Kowalick [1], R. Paul [1], M. Zinecker [1], D. Kuhn [1], G. Meichsner [2], A. Schubert [3],
[1] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany
[2] Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
[3] Professorship Micromanufacturing Technology, Technische Universität Chemnitz, Chemnitz, Germany; Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany

This study presents investigations on a developed process design for manufacturing internal precision geometries by pulsed electrochemical machining (PECM) with help of multiphysics simulations. Therefore, a 2D axisymmetric transient model was created. The considered physical phenomena ... Read More

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