An Investigation of Rapid Tooling for Electrochemical Machining of Ti-6Al-4V Alloy

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dc.contributor.advisor Ola L. A. Harrysson, Committee Member en_US
dc.contributor.advisor Stephen D. Roberts, Committee Member en_US
dc.contributor.advisor Denis R. Cormier, Committee Chair en_US Srisawadi, Sasitorn en_US 2010-04-02T18:12:32Z 2010-04-02T18:12:32Z 2006-05-04 en_US
dc.identifier.other etd-04272006-110702 en_US
dc.description.abstract This thesis investigates the feasibility of rapid tooling for Electrochemical Machining (ECM). For a variety of reasons, ECM is an attractive process for finish machining of near net shape components built via direct metal freeform fabrication techniques such as Electron Beam Melting (EBM). These processes are typically used with high dollar value alloys such as titanium (Ti-6Al-4V). An experimental pulsed ECM system was constructed, and physical experiments were conducted. Laser profilometry was used to measure surface roughness and material removal. Results indicated that electrode voltage and gap size have the largest influence on surface roughness and material removal. These experiments demonstrated the feasibility of electrochemically machining titanium using copper plated stereolithography electrodes. Based upon visual inspection and optical micrographs, sludge build-up was observed in corners of the machined pockets. Inefficient electrolyte flushing was believed to be the cause of this problem, and a new through-electrode flushing technique is proposed. Computational fluid dynamic simulations indicate that through-electrode flushing can produce a much more effective flow path across the work piece surface, thus increasing flushing effectiveness. en_US
dc.rights I hereby certify that, if appropriate, I have obtained and attached hereto a written permission statement from the owner(s) of each third party copyrighted matter to be included in my thesis, dissertation, or project report, allowing distribution as specified below. I certify that the version I submitted is the same as that approved by my advisory committee. I hereby grant to NC State University or its agents the non-exclusive license to archive and make accessible, under the conditions specified below, my thesis, dissertation, or project report in whole or in part in all forms of media, now or hereafter known. I retain all other ownership rights to the copyright of the thesis, dissertation or project report. I also retain the right to use in future works (such as articles or books) all or part of this thesis, dissertation, or project report. en_US
dc.subject Surface roughness en_US
dc.subject Finishing en_US
dc.subject Rapid tooling en_US
dc.subject ECM en_US
dc.subject Electrochemical machining en_US
dc.title An Investigation of Rapid Tooling for Electrochemical Machining of Ti-6Al-4V Alloy en_US MS en_US thesis en_US Industrial Engineering en_US

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