Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys
The application of titanium alloy parts manufactured by high-speed additive manufacturing in industry is currently constrained by the low surface accuracy. This severely constrains the potential of high-speed additive manufacturing for processing aerospace titanium alloy components. To address this...
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| Format: | Article |
| Language: | English |
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2430328 |
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| author | Yang Liu Xinyu Liu Jinzhong Lu Zhaoyang Zhang Kaiyu Luo Shu Huang Haifei Lu Gang Xu Guoqing Dai Siyu Zhou |
| author_facet | Yang Liu Xinyu Liu Jinzhong Lu Zhaoyang Zhang Kaiyu Luo Shu Huang Haifei Lu Gang Xu Guoqing Dai Siyu Zhou |
| author_sort | Yang Liu |
| collection | DOAJ |
| description | The application of titanium alloy parts manufactured by high-speed additive manufacturing in industry is currently constrained by the low surface accuracy. This severely constrains the potential of high-speed additive manufacturing for processing aerospace titanium alloy components. To address this issue, it is crucial to address the high-speed additive manufactured rough surface in order to enhance surface accuracy. As a highly flexible non-contact machining method, electrochemical jet machining is well-suited for surface post-treatment of additive manufactured titanium alloy parts due to its distinctive advantages, including the absence of tool loss, no cutting force, and no thermal effects. This paper examines the electrochemical jet machining of rough low-precision surfaces produced by high-speed additive manufacturing. The distribution characteristics of the machining electric field and machining flow field on extremely rough additive manufactured surfaces were investigated through simulation. A series of experiments were conducted to verify the effectiveness of the simulation. The research findings indicated that the cut-in electrochemical jet machining method effectively circumvented the adverse effects of rough surfaces on electrolyte flow, thereby allowing for high-quality machining. The surface roughness of titanium alloy samples produced by high-speed additive manufacturing was reduced from Ra 21.179–1.838 um, representing a 90% reduction. |
| format | Article |
| id | doaj-art-f04c9efaab764f20ad336b3f5fecb41b |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-f04c9efaab764f20ad336b3f5fecb41b2025-02-02T19:44:06ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2024.2430328Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloysYang Liu0Xinyu Liu1Jinzhong Lu2Zhaoyang Zhang3Kaiyu Luo4Shu Huang5Haifei Lu6Gang Xu7Guoqing Dai8Siyu Zhou9School of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaSchool of Mechanical Engineering, Jiangsu University, Zhenjiang, People’s Republic of ChinaCollege of Materials Science and Engineering, Nanjing Tech University, Nanjing, People’s Republic of ChinaSchool of Mechatronics Engineering, Shenyang Aerospace University, Shenyang, People’s Republic of ChinaThe application of titanium alloy parts manufactured by high-speed additive manufacturing in industry is currently constrained by the low surface accuracy. This severely constrains the potential of high-speed additive manufacturing for processing aerospace titanium alloy components. To address this issue, it is crucial to address the high-speed additive manufactured rough surface in order to enhance surface accuracy. As a highly flexible non-contact machining method, electrochemical jet machining is well-suited for surface post-treatment of additive manufactured titanium alloy parts due to its distinctive advantages, including the absence of tool loss, no cutting force, and no thermal effects. This paper examines the electrochemical jet machining of rough low-precision surfaces produced by high-speed additive manufacturing. The distribution characteristics of the machining electric field and machining flow field on extremely rough additive manufactured surfaces were investigated through simulation. A series of experiments were conducted to verify the effectiveness of the simulation. The research findings indicated that the cut-in electrochemical jet machining method effectively circumvented the adverse effects of rough surfaces on electrolyte flow, thereby allowing for high-quality machining. The surface roughness of titanium alloy samples produced by high-speed additive manufacturing was reduced from Ra 21.179–1.838 um, representing a 90% reduction.https://www.tandfonline.com/doi/10.1080/17452759.2024.2430328 |
| spellingShingle | Yang Liu Xinyu Liu Jinzhong Lu Zhaoyang Zhang Kaiyu Luo Shu Huang Haifei Lu Gang Xu Guoqing Dai Siyu Zhou Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys Virtual and Physical Prototyping |
| title | Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys |
| title_full | Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys |
| title_fullStr | Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys |
| title_full_unstemmed | Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys |
| title_short | Multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high-speed additive manufactured titanium alloys |
| title_sort | multiphase flow simulations and experiments on electrochemical jet machining of rough surfaces of high speed additive manufactured titanium alloys |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2024.2430328 |
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