Hybrid Electrochemical Machining of Advanced Alloys (HEMAA) (HEMAA)

The project aims to conduct collaborative research work on hybrid electrochemical machining (ECM) theory and method for advanced alloys. The technology of machining advanced materials, such as titanium alloy and nickel alloys, is of great importance to aerospace and marine industries which requires high-performance components for aeroengines and deep drilling tools for marines. The hybrid machining process is regarded as the most effective way to machine these materials. In this project, researchers from KU Leuven (KUL) and Shanghai Jiao Tong University (SJTU) will collaborate on investigating the fundamental knowledge in ECM based hybrid machining technologies. The project will focus on development and fundamental study of three novel hybrid machining methods, which are depicted in the following units:

Unit A:

Title: Ultrasonic assisted Mechano Electrochemical Milling (UMECM)

Investigators: Prof. Dr. LAUWERS Bert(KUL), Dr. QIAN Jun(KUL), Dr. GUO Yansong(KUL), Ir. VAN CAMP Dries(KUL)

The goal of this group is to develop a novel hybrid ECM process, namely ultrasonic assisted mechano electrochemical milling (UMECM).  The following development and fundamental researches will be conducted with the help of theoretical study, experiments and numerical analysis: (1) The UMECM process will be developed by integrating ultrasonic vibration and milling into the ECM process; (2) The material removal mechanism of UMECM; (3) Quantitative relation between process variables (e.g. voltage, current) and process quality (e.g. surface integrity, tool wear). This group will be responsible to disclose the sealed mechanisms, solve the scientific puzzle and discover the quantitative machining characteristics of this innovative hybrid ECM method.

Unit B:

Title: Electrochemical Discharge Machining (ECDM)

Investigators: Prof. ZHAO Wansheng(SJTU), Dr. KANG Xiaoming(SJTU), Dr. Gu Lin(SJTU), Dr. Xi Xuecheng(SJTU)

The goal of this group is to study the evolution of bubbles, the characteristics of discharge and their effects on the material removal. The following fundamental researches will be conducted by experimental observation and numerical analysis: (1) The mechanism of bubbles evolution around the tool electrode; (2) The characteristics of discharge generation; (3) The mechanism of material removal. This group will have the responsibilities to disclose the mechanisms of the hybrid machining method, and to find a scientific solution to improve the machining performance of ECDM.

Unit C:

Title: Title: Laser assisted Electrochemical Jet Machining (LECJM)

Investigators: Prof. ZHAO Wansheng(SJTU), Dr. ZHANG Yaou(SJTU), Dr. Pei Jingyu(SJTU), Dr. Chen Mo(SJTU)

The goal of this group is to develop a novel high aspect ratio micro deep hole machining method named Laser assisted Electrochemical Jet Machining (LECJM). The following development and fundamental researches will be conducted both numerically and experimentally: (1) The LECJM process will be developed by integrating laser beam into the Electrochemical Jet Machining process to localize the electrolytic machining zone; (2) The material removal mechanism of LECJM; (3) The machining characteristics of LECJM. This group will have the responsibilities to disclose the machining mechanisms of LECJM, and to find a scientific solution to improve the machining performance of LECJM.