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Krotz H.,Institute of Machine Tools and Manufacturing | Krotz H.,EMAG eldec Induction GmbH | Wegener K.,Institute of Machine Tools and Manufacturing
International Journal of Advanced Manufacturing Technology | Year: 2015

This paper details the fundamental principles of the machining method spark assisted electrochemical machining (SAEM). SAEM is a further development of the electrochemical arc machining (ECAM) which makes use of the electrochemical discharge phenomenon to machine electrically conductive materials. ECAM is not able to drill micro-holes, but now, using SAEM a postponed electrochemical finishing of the SAEM drilled micro-hole can be realized. The mass flow calibration of a throttle plate can be done immediately after SAEM microdrilling by electrochemical machining (ECM) with a still axis-symmetrically located tool electrode with the same machining equipment, working media, and power source. To enable ECAM to drill micro-holes, its material removal mechanism is improved by combination with the contact arc as an additional mechanism. This mechanism is presented and explained herein. The machining efficiency of the newly developed SAEM is optimized by adjusting the gap control in such a way that the contact arc is generated with an adequate frequency. This reduces the machining time by almost 50 %. Some examples of SAEM drilled micro-holes, for which different electrolytes are used, are presented and the surface and heat affected zone of those micro-holes are examined. © 2015, Springer-Verlag London. Source


Krotz H.,Institute of Machine Tools and Manufacturing | Krotz H.,Eldec Schwenk Induction GmbH | Roth R.,Institute of Machine Tools and Manufacturing | Wegener K.,Institute of Machine Tools and Manufacturing
International Journal of Advanced Manufacturing Technology | Year: 2013

In this work, single discharges of electrochemical arc machining are examined. The heat-affected zone is analyzed, and a model is set up to simulate the heat transfer into the workpiece. As an input parameter of the simulation, the temperature of the electrochemical arc machining process was determined to be 3,500 K by means of emission spectroscopy. The simulation shows that the diameter of the heat-affected zone is less dependent on discharge duration and heat transfer due to heat flux than on the arc spot diameter. As a result of the investigation, it became clear that varying diameters of the heat-affected zone have to evolve from different diameters of the plasma channel's arc spot. Understanding the heat distribution into the workpiece in electrochemical arc machining with micro-machining parameters allows the further development of a micro-drilling process for electrically conductive materials based on electrochemical arc machining. © 2013 Springer-Verlag London. Source

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