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Pulse electrochemical machining of cast iron: a layer-based approach for modeling the steady-state dissolution current

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Abstract

In this paper, a new layer-based simulation method for predicting the steady-state current of a pulse electrochemical machining (PECM) process is described. The basic concept of the method is a simple two-layer model consisting of a porous oxide and an adsorption layer. The oxide layer of PECM-machined samples, characterized by Raman spectroscopy and electron microscopy measurements, shows a similar structure as the oxide layer formed in electrochemical impedance spectroscopy (EIS) measurements. Therefore, the electronic equivalent circuit developed according to EIS results was used as analogy for the description of the overall impedance of the PECM model. The difference between the assumed layers of a PECM and EIS measurement is modeled with a material-dependent adjustment function. In this way, the calculated values of the equivalent circuit elements can be directly derived from experimental PECM data. It could be shown that the procedure allows the calculation of the steady-state current of PECM processes for different work conditions (e.g., pulse on-times, pulse frequencies). The procedure is applied to the electrochemical dissolution of three different types of cast iron in NaNO3 electrolyte on realistic machining conditions. All samples were characterized according to their chemical composition, graphite particle morphology/structure, and their anodic dissolution behavior.

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Acknowledgments

This work was financially supported by the European Union within the Interreg IV A program “Initiative PRECISE.” We thank Prof. Dr. Rolf Hempelmann and Dipl.-Ing. Martin Weinmann for fruitful discussions and the experimental support.

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Authors and Affiliations

  1. Production Engineering, Saarland University, Campus A4 2, 66123, Saarbrücken, Germany

    Olivier Weber & Dirk Bähre

  2. Center for Mechatronics and Automation, Gewerbepark Eschberger Weg, Geb. 9, 66121, Saarbrücken, Germany

    Olivier Weber

  3. Physical Chemistry, Saarland University, Campus B2 2, 66123, Saarbrücken, Germany

    Harald Natter

Authors
  1. Olivier Weber
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  2. Harald Natter
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  3. Dirk Bähre
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Correspondence to Harald Natter.

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Weber, O., Natter, H. & Bähre, D. Pulse electrochemical machining of cast iron: a layer-based approach for modeling the steady-state dissolution current. J Solid State Electrochem 19, 1265–1276 (2015). https://doi.org/10.1007/s10008-014-2735-1

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  • DOI: https://doi.org/10.1007/s10008-014-2735-1

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