Improvement on leveling ability in counter-rotating electrochemical machining by using a variable voltage

IF 2.9 3区 工程技术 Q2 AUTOMATION & CONTROL SYSTEMS
Guowei Cui, Dengyong Wang, Zengwei Zhu, Wenjian Cao, Tianyu Fu
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Abstract

Roundness error plays an important role of rotating parts in engineering fields and it has a significant influence on the machining quality and accuracy during electrochemical machining (ECM) process. The precision ECM could be processed only if the initial roundness error is decreased or eliminated and the inter-electrode gap (IEG) becomes steady after reaching an equilibrium state. However, a constant voltage is generally used in ECM process. And a long time and a large allowance are required to level the profile error of workblank if the initial profile error is large. In this study, the focus herein is on the acceleration of the leveling process of the rotary workpiece. A counter-rotating electrochemical machining (CRECM) process method with a variable voltage is proposed to improve the leveling ability. For a rotary workpiece with elliptical contours, the machining voltage can be dynamically adjusted based on the IEG through the approximate regulation of sine waves according to modeling-based analysis. The method aims to improve the leveling ability by expanding the difference in the magnitude of electric current between the high and low points on the profile of the anode workpiece under different voltages. The results of experiments confirmed that the proposed method significantly reduced the leveling time from 36 to 7 min (by 81%), and the depth of dissolution of the highest point on the profile from 1.68 to 0.45 mm while reducing the roundness error from 0.5 to 0.05 mm. The leveling ratio increased from 0.26 to 0.99.

Abstract Image

使用可变电压提高反向旋转电化学加工的平整能力
在工程领域,圆度误差对旋转零件起着重要作用,它对电化学加工(ECM)过程中的加工质量和精度有重大影响。只有减少或消除初始圆度误差,并使电极间隙 (IEG) 达到平衡状态后趋于稳定,才能加工出精密的 ECM。然而,在 ECM 加工中通常使用恒定电压。如果初始轮廓误差较大,则需要较长的时间和较大的余量来消除工件毛坯的轮廓误差。本研究的重点是旋转工件矫平过程的加速。为提高矫平能力,提出了一种带可变电压的反转电化学加工(CRECM)工艺方法。对于轮廓为椭圆形的旋转工件,可根据建模分析,通过近似调节正弦波,根据 IEG 动态调节加工电压。该方法旨在通过扩大不同电压下阳极工件轮廓上高点和低点之间的电流大小差来提高矫平能力。实验结果证实,所提出的方法大大缩短了整平时间,从 36 分钟缩短到 7 分钟(缩短了 81%),剖面上最高点的溶解深度从 1.68 毫米减少到 0.45 毫米,圆度误差从 0.5 毫米减少到 0.05 毫米。整平率从 0.26 提高到 0.99。
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来源期刊
CiteScore
5.70
自引率
17.60%
发文量
2008
审稿时长
62 days
期刊介绍: The International Journal of Advanced Manufacturing Technology bridges the gap between pure research journals and the more practical publications on advanced manufacturing and systems. It therefore provides an outstanding forum for papers covering applications-based research topics relevant to manufacturing processes, machines and process integration.
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