Ultrasound - Composite Electrolytic Micro-machining Applications Of Basic Research

In this paper, the concept of micro-machining and its technical characteristics are outlined. Meanwhile, the processes used in combined-machining and micro non-traditional machining technologies are introduced. Furthermore, the importance of micro-machining about USM(ultrosonic machining) and ECM (electrochemical machining) is analyzed and emphasized.Based on these theories, the combined micro-machining technology of USM and ECM is proposed, then study content and research object of this paper are confirmed.Besides, the mechanism , equipment and process limitations of USM and ECM are also summarized. Accordingly, the process requirements of the combined technology is suggested.Then, a discussion is further given about the necessity, feasibility and advantagement of combined micro-machining of USM and ECM.According to the micro-machining technology and its characteristic , experimental system of combined micro-machining of USM and ECM is built up, its machining parameters could be adjusted in a wide range, including the hydraulic device that used to adjust the contact pressure between cathode and workpiece, the design and manufacturing of amplitude transformer horn, supply of electrolyte and abradant granularity, precise localization of workpiece, parameter detection, measurement of machining precision and so on . All of the above provides experimental condition for the later research work.In addition, the manufacturing process of micro cathodes is a key for the combined micro-machining of USM and ECM, So after detailed analyse on the working characteristic and manufacturing difficulty of cathodes, combined electrical discharge machining is proposed to make cathodes that will be used in later tests, including the"copy adding translate","multi-axle linking feeds". With these means, experimental cathodes with diffirent cross sections could be made and the general means are summarized.During the experiment, the solo ultrasonic machining experiments are carried out on piezoelectric ceramics, silicon sheet and cemented carbide. Then combined micro-machining of USM and ECM is done on the cemented carbides. Whereafter detailed analyse is made on the machining precision, abrasion wear of the cathode and efficiency, including the influence of electrolyte, electrical parameters (voltage, pulse parameter), amplitude, frequency, contact pressure and abradant granularity. The possibility, feasibility and advantages of the combined micro-machining technology used in machining micro elements is confirmed, all of which provide the basic condition in the application of combined micro-machining of USM and ECM.In the end, the technology characteristics of this micro-machining is analyzed and summarized .Furthermore, process problems, shortage and its improvement means are also suggested. Then further study works are put forward.