成果報告書詳細
管理番号20150000000416
タイトル*平成26年度中間年報 SIP(戦略的イノベーション創造プログラム) 革新的設計生産技術 次世代型高性能電解加工機の研究開発(2)
公開日2015/7/18
報告書年度2014 - 2014
委託先名国立大学法人東京農工大学
プロジェクト番号P14030
部署名ロボット・機械システム部
和文要約
英文要約Title: Development of High-performance Electrochemical Machining System of Next Generation (FY2014-FY2015) FY2014 Annual Report

The project “Development of High-performance Electrochemical Machining System of Next Generation” is composed of following three sub-projects. The second sub-project is collaboratively carried out by Tokyo University of Agriculture and Technology, the University of Tokyo, Toyota Technological Institute, Kanto Gakuin University, and Shizuoka Institute of Science and Technology.
Sub-project 1: Elucidation of electrochemical machining phenomenon and development of simulation technology
Sub-project 2: Development of high value-added parts machining method
Sub-project 3: Development of high-precision electrochemical machining system
In this report, main development achievements of the second sub-project in this fiscal year are summarized.

(1) Micro electrochemical machining
The detection and control of inter-electrode distance for the electrostatic induction feeding method was carried out experimentally. Also, in order to improve the processing rate, an electrolytic cell was designed and fabricated, and the circuit parameters of the equivalent circuit for electrochemical machining were obtained through comparing the experiment results with the computed ones. The main achievement is that the parameters of the anode and cathode were successfully classified by using different electrode materials. In addition, the influences of applied voltage, the type and concentration of the electrolyte solution on the parameters were investigated. By comparing the analytical results with some generally-known ECM phenomena, the effectiveness of parameter determination was verified.

(2) Electrochemical machining for hard-to-machine materials
Since the passive film generates on the processed surface during ECM, the titanium alloy and cemented carbide are typical hard-to-machine materials, not only in cutting process but also in ECM process. In this study, in order to remove the passive film during ECM with neutral electrolyte, ultrasonic vibration machining or mechanical polishing was combined with ECM. The experimental devices were designed and constructed. Also, the method to generate complicated shape by scanning a small polishing tool was proposed and examined. The experimental results show that titanium alloy can be effectively processed by combining ECM with mechanical polishing, and a free form shape can be generated by controlling the scanning path and speed of polishing tool. In addition, ECM characteristics for the cemented carbide material, especially influences of the waveform of power supply and the kind of electrolyte, were investigated. Also, the turning processing of cemented carbide by electrolyte jet machining was conducted, and the relationship between the workpiece rotating speed and the machined shape was examined.
As for machining insulating glass rod with a lathe-type electro-chemical discharge machine, the force control device was designed and constructed based on experimentally obtained results.

(3) Electrochemical machining for complicated shapes
In order to realize practical application of electrochemical machining to the internal cooling channel for molds, massive sludge has to be removed from the machining area effectively. A tool electrode device equipped with ultrasonic vibration function was designed and fabricated, in order to remove the sludge from the bending cooling channel during machining.
On the other hand, although an electrolyte suction tool is effective to create complex shapes, a large amount of air was sucked into the machining area with the electrolyte solution during processing. As a result, electrical discharges occurred and the machining speed reduced.
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