Simulation-based fabrication of micro-helical grooves in a hydrodynamic thrust bearing by using ECMM

Jung Chou Hung, Chen Hui Chang, Kuan Chih Chiu, Shuo Jen Lee

Research output: Contribution to journalArticlepeer-review

12 Scopus citations

Abstract

In hydrodynamic thrust bearing, common micro-grooves with helical or herringbone forms are generally to ensure the bearing load capacity and reduce leakage of lubricant, consistent with the design or size requirements of grooves. In this investigation, the electrical field distribution and anodic dissolution of helical grooves in electrochemical micro-machining process can be predicted by using COMSOL MultiphysicsTM software. The processing equivalent is based on the chemical composition of the workpiece. The micro-helical grooves are hollowed out of hydrodynamic thrust bearing using a DC and pulse power supply, and experiment results are compared with simulation results. The experimental results demonstrate that the fine surface of helical grooves can be obtained with a depth of 4.9 μm in machining time of 3 s by using a pulse power supply of 5 kHz. To eliminate the effect of such factors as flush flow, temperature difference between workpiece and tool, and formation of hydrogen bubble barriers, the k values of these factors are considered for amendment to get more accurate simulation results.

Original languageEnglish
Pages (from-to)813-820
Number of pages8
JournalInternational Journal of Advanced Manufacturing Technology
Volume64
Issue number5-8
DOIs
StatePublished - Feb 2013

Keywords

  • Electrochemical micro-machining
  • Hydrodynamic thrust bearing
  • Micro-helical groove
  • Modeling simulation

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