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Introduction
Companies working in the metal sector are faced with the problem of labeling
the metals when they do not have planar surfaces.
That is why the main idea of this project is constructing of an electrochemical
tool for labeling metal parts with complex surfaces, and calculating regimes of
the labeling.
Another problem that can occur is that there are more than hundred different
kinds of metals and many more alloys. For a metal sector company must be
necessary to label all this metals and alloys. Then, will be easier to recognize
what metal is that is needed.
The method that will be used for making possible that the tool work is the
Electrical Discharge Machining (EDM), with the electrode shape variant. Known
as Ram EDM.
The EDM is a machining method that is based on two phenomena, the
electrochemical dissolution of the material and thermal erosion due to electrical
discharges (sparks) that occur between the electrodes (workpiece and tool).
The electrode selected for this tool is a Graphite electrode because it has got a
high temperature of vaporization and is more resistant than other materials.
With this electrode the problem about the erosion in the electrode is solved, and
when the erosion appears is not a problem to change the tool because it has a
low price compared to other materials such as copper, tungsten, platinum,
molybdenum…whose price is much higher.
The dielectric fluid that is going to be used is Kerosene because it has the best
properties for the EDM proceedings. Kerosene has no rust problems and
compared with deionized water has not produced dangerous gasses.
After designing the tool it will be designed a distribution channel where the
dielectric fluid will circulate, inside these pipes there will be some ventilator with
filter whose work is to clean the fluid for a correct electrical conductivity.
Aims of Project
The main purpose of this project is to design a tool for labeling metals that have
non-planar or complex surfaces.
The principal idea making this report is to learn about electrochemical process,
about the electrochemistry area in the engineering.
The investigation research has given extensive knowledge on the subject and
the necessity to solve problems help in this learning area.
It has gained extensive knowledge of electrochemical processes, with emphasis
on the EDM. (Materials, processes, lubricants, dielectric fluids ...)
Moreover, it has also developed skills in the design field, having to design
different parts of the system.
And finally, in the mechanical aspect also has to study how to calculate different
measures.
Definition of Electrochemistry1
Electrochemistry is a branch of chemistry that studies the transformation
between electrical and chemical energy. In other words, the chemical reactions
that that take place at the interface of an electrical conductor, the electrode (that
can be a metal or a semiconductor) and an ionic conductor, the electrolyte.
That is why electrochemistry has been separated into two main sections. The
first is electrolysis, which refers to those chemical reactions that occur due to
the action of an electric current. The second is referred to those chemical
reactions that generate an electrical current.
3.2 Electrical Discharge Machining (EDM)2
3.2.1 Definition
Electric discharge machining (EDM) is a manufacturing process whereby a
desired shape is obtained using electrical discharges (sparks). Material is
removed from the workpiece by a series of rapidly recurring current discharges
between two electrodes, separated by a dielectric liquid and subject to an
electric voltage. One of the electrodes is called the tool-electrode, or simply the
‘tool’ or ‘electrode’, while the other is called the workpiece-electrode, or
‘workpiece’.