INVESTIGATION INTO CURRENT EFFICIENCY FOR PULSE ELECTROCHEMICAL MACHINING OF NICKEL ALLOY

INVESTIGATION INTO CURRENT EFFICIENCY FOR PULSE ELECTROCHEMICAL MACHINING OF NICKEL ALLOY Yu Zhang, M.S. University of Nebraska, 2010 Adviser: Kamlakar P. Rajurkar Electrochemical machining (ECM) is a nontraditional manufacturing process that can machine difficult-to-cut materials. In ECM, material is removed by controlled electrochemical dissolution of an anodic workpiece in an electrochemical cell. ECM has extensive applications in automotive, petroleum, aerospace, textile, medical, and electronics industries. Improving current efficiency is a challenging task for any electro-physical or electrochemical machining processes. The current efficiency is defined as the ratio of the observed amount of metal dissolved to the theoretical amount predicted from Faraday’s law, for the same specified conditions of electrochemical equivalent, current, etc [1]. In macro ECM, electrolyte conductivity greatly influences the current efficiency of the process. Since there is a certain limit to enhance the conductivity of the electrolyte, a process innovation is needed for further improvement in current efficiency in ECM. Pulse electrochemical machining (PECM) is one such approach in which the electrolyte conductivity is improved by electrolyte flushing in pulse off-time. The aim of this research is to study the influence of major factors on current efficiency in a pulse electrochemical machining process in macro scale and to develop a linear regression model for predicting current efficiency of the process. An in-house designed electrochemical cell was used for machining nickel alloy (ASTM B435) by PECM. The effects of current density, type of electrolyte, and electrolyte flow rate, on current efficiency under different experimental conditions were studied. Results indicated that current efficiency is dependent on electrolyte, electrolyte flow rate, and current density. Linear regression models of current efficiency were compared with twenty new data points graphically and quantitatively. Models developed were close enough to the actual results to be reliable. In addition, an attempt has been made in this work to consider those factors in PECM that have not been investigated in earlier works. This was done by simulating the process by using COMSOL software. However, it was found that the results from this attempt were not substantially different from the earlier reported studies.

A Comparison of Induction Motor Starting Methods Being Powered by a Diesel-Generator Set

Starting induction motors on isolated or weak systems is a highly dynamic process that can cause motor and load damage as well as electrical network fluctuations. Mechanical damage is associated with the high starting current drawn by a ramping induction motor. In order to compensate the load increase, the voltage of the electrical system decreases. Different starting methods can be applied to the electrical system to reduce these and other starting method issues. The purpose of this thesis is to build accurate and usable simulation models that can aid the designer in making the choice of an appropriate motor starting method. The specific case addressed is the situation where a diesel-generator set is used as the electrical supplied source to the induction motor. The most commonly used starting methods equivalent models are simulated and compared to each other. The main contributions of this thesis is that motor dynamic impedance is continuously calculated and fed back to the generator model to simulate the coupling of the electrical system. The comparative analysis given by the simulations has shown reasonably similar characteristics to other comparative studies. The diesel-generator and induction motor simulations have shown good results, and can adequately demonstrate the dynamics for testing and comparing the starting methods. Further work is suggested to refine the equivalent impedance presented in this thesis.