Precision improvements in ECM via tool insert development by 3D printing

• This paper reports the tool developments for electrochemical machining (ECM) of precision parts for automotive industry using polymer3D printed inserts. The role of these inserts is to control the fluid flow in the inter-electrode gap as well as to prevent stray machiningby providing insulation. Initial trial and error machining experiments with various tool insert shapes yielded positive outcomes in terms ofcontrolling stray dissolution. It became evident that by 3D printing the entire machining cell structure with integrated, exchangeable toolinserts, all made from polymer, can further enhance the ECM process. This cell-insert assembly enabled better control of the electrochemicaldissolution process and allowed for less restrictive flow of the electrolyte, reducing turbulence in the inter-electrode gap. Thus, by improvingthe electrolyte flow conditions and providing appropriate insulation to prevent stray machining, the 3D printed cell/insert assemblies enabledECM to achieve a shaped profile of an auto engine component to required tolerances.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik -- Produktionsteknik, arbetsvetenskap och ergonomi (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering -- Production Engineering, Human Work Science and Ergonomics (hsv//eng)

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Bearbetnings-, yt- och fogningsteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Manufacturing, Surface and Joining Technology (hsv//eng)

Nyckelord

ECM

3D printing

Dissolution control

Maskinteknik

Mechanical Engineering

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