Research On Process Parameters And Equipment Of Aluminum Electrolyte-plasma Polishing

Electrolyte-Plasma polishing is a new type of high efficient polishing technology, itis used for processing on the surface of metal parts with complex shape. It will lowerthe surface roughness value of parts and improve the brightness of parts. The methodhas the advantages of high machining quality and the consistency of parts afterprocessing is very good. And the efficiency of electrolyte-plasma polishing is higherthan other traditional polishing methods. At present, the method has a ideal processingeffect for stainless steel, copper alloy and low carbon steel metal parts. But theprocessing effect of aluminum alloy is not very stable because the method has’t foundthe optimal process parameters. In order to solve this problem, improve the surfacequality and polishing process, this thesis has made a research on the method ofelectrolyte-plasma polishing.Firstly, on the basis of the study on electrolyte-plasma polishing mechanism, thethesis has designed the main structure of machine tool according to requirements ofprocess parameters. It has completed building the50KW experiment platform ofelectrolyte-plasma polishing. And the work lays the foundation for the follow-up studyon process of aluminum alloy electrolyte-plasma.Secondly, this thesis has chosen roughness and reflectivity as index for evaluationof the effect of aluminum alloy polishing. The thesis detects the roughness of parts bycombining TR200roughness tester with scanning force microscope. The thesis hasdesigned the optical path meeting the test requirements for the detection of reflectivity.According to surface roughness and reflectivity, this thesis has designed a orthogonaltest of four factors and four levels by selecting temperature, processing time, depth,space angle as Reference volume. Based on the analysis of test results, the thesis has gotthe primary and secondary sequence of factors for the effect of processing quality. Thethesis has also got the optimal combination of process parameters at which it will getthe lowest surface roughness values and the highest reflectivity.In addition, the thesis presents an improved polishing method by combiningelectrolyte-plasma polishing with electrolytic polishing to make the processing surfacebetter after electrolyte-plasma polishing. And the thesis build the experiment platformof the electrolytic polishing. By contrasting the roughness and reflectivity of sample ofbefore and after optimization, the surface roughness is reduced from10.2nm to9.3nm,and the reflectivity is improved from48.87%to50.05%. The optimizational result isreally better than electrolyte-plasma polishing, it doesn’t only verify the feasibility ofoptimization method, but also points out the direction for later research on electrolyte-plasma polishing.