Numerical simulation and experimental research on through-mask electrochemical machining of micro-dimple arrays using inner-jet cathodes

IF 1.9 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
Feng Wang, Tao Wang, Yafeng He, Zhiqiang Yu, Yiming Shen, M. Kang
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引用次数: 0

Abstract

The surface micro-dimple arrays can effectively improve the friction and lubrication performance of moving parts and are widely used in cutting tools and mechanical transmissions. Through-mask electrochemical machining (TMECM) is a process that uses the anodic dissolution principle to remove materials at low temperatures. It is suitable for efficiently processing large-area micro-dimple arrays on metal surfaces. However, the previous TMECM method still suffers from the problem of low processing adaptability. In this paper, a new method for scanning-cathode TMECM by utilizing the fluid dynamic pressure effect was proposed, and the flow field and electric field models of various inner-jet cathodes were developed as well. Through numerical simulations of the flow field and electric field, the flow velocity, electrolyte pressure, and current density distributions for different inner-jet cathodes were investigated to determine an appropriate cathode. Contrasting experiments were conducted to investigate the variations in electrolyte flow states and machining currents for different inner-jet cathodes. Additionally, the changes in micro-dimple dimensions under different machining parameters were investigated. Moreover, the micro-dimple arrays of 385.7 μm in diameter and 111.8 μm in depth, 288.8 μm in diameter and 40.3 μm in depth, and micro-dimple arrays with an etching factor of 1.69 were fabricated, and the results demonstrated the good processing adaptability of the scanning-cathode TMECM.
使用内喷射阴极对微脆性阵列进行通罩电化学加工的数值模拟和实验研究
表面微脆性阵列可有效改善运动部件的摩擦和润滑性能,被广泛应用于切削工具和机械传动中。掩膜电化学加工(TMECM)是一种利用阳极溶解原理在低温下去除材料的工艺。它适用于高效加工金属表面上的大面积微凹陷阵列。然而,以往的 TMECM 方法仍然存在加工适应性不强的问题。本文提出了一种利用流体动压效应的扫描阴极 TMECM 新方法,并建立了各种内喷射阴极的流场和电场模型。通过流场和电场的数值模拟,研究了不同内喷射阴极的流速、电解质压力和电流密度分布,从而确定了合适的阴极。通过对比实验,研究了不同内喷射阴极的电解液流动状态和加工电流的变化。此外,还研究了不同加工参数下微凹痕尺寸的变化。此外,还制作了直径为 385.7 μm、深度为 111.8 μm、直径为 288.8 μm、深度为 40.3 μm、蚀刻因子为 1.69 的微窦阵列,结果表明扫描阴极 TMECM 具有良好的加工适应性。
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来源期刊
CiteScore
5.10
自引率
30.80%
发文量
167
审稿时长
5.1 months
期刊介绍: Manufacturing industries throughout the world are changing very rapidly. New concepts and methods are being developed and exploited to enable efficient and effective manufacturing. Existing manufacturing processes are being improved to meet the requirements of lean and agile manufacturing. The aim of the Journal of Engineering Manufacture is to provide a focus for these developments in engineering manufacture by publishing original papers and review papers covering technological and scientific research, developments and management implementation in manufacturing. This journal is also peer reviewed. Contributions are welcomed in the broad areas of manufacturing processes, manufacturing technology and factory automation, digital manufacturing, design and manufacturing systems including management relevant to engineering manufacture. Of particular interest at the present time would be papers concerned with digital manufacturing, metrology enabled manufacturing, smart factory, additive manufacturing and composites as well as specialist manufacturing fields like nanotechnology, sustainable & clean manufacturing and bio-manufacturing. Articles may be Research Papers, Reviews, Technical Notes, or Short Communications.
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