Ultrasound-assisted Electroformed Cu/TiB₂ EDM Electrode

Tool electrode of electrical discharge machining(EDM) is fabricated by electroforming process, which could meet varieties of mechanical properties with a high level of accuracy and reproducibility. Electroforming is an electrolytic process that enables the ions of metallic parts deposited onto a model part and later released from it. Due to its features, elecform3 d surface, fine pattern, intricate parts, complex shapes have much advantages over some replication manufacturing tasks. Metal removal mechanism in EDM is mainly a thermal phenomenon where thermal energy is produced in plasma channel, and is dissipated though work piece, tool and dielectric. However the main disadvantage of EDM is the tool wear. In this process a copper matrix composites reinforced with a network of Ti B2 compounds are fabricated via ultrasonic assistive electroforming technologies. Electroforming are the non-uniform thickness distribution and the high time of processing. This product work enables better thickness uniformity as well as lower time manufacturing, achieving High Speed Electroforming therefore enabling new application fields. The main research contents and conclusions are as follows:(1)The aim of this work is to optimize electroforming parameters by orthogonal experiment and variance analysis and pursue the influence of four factors electric current density, solution temperature, Ti B2 particle size and optimal combination parameters of electroforming of Ti B2 by index the results of electroforming layer surface microstructure morphology, hardness and corrosion resistance. The results show that Ti B2 particles distributed evenly on copper matrix organization have a significant effect of refining, without a lot of reunion phenomenon; compared to electroforming elemental Cu, Cu/Ti B2 composites close to the smallest of the average grain diameter, high hardness, and good corrosion resistance.(2) The aim of this work is to study the effect of ultrasound on the electroforming. In ultrasonic power to 0 w, 50 w and 100 w and 150 w under the electroforming Cu/Ti B2, it is concluded that when the ultrasonic power is 100 w, electroforming Cu/Ti B2 compare to other electroforming process under the surface smoother, minimum average grain diameter, high hardness, corrosion resistance is best. Ultrasonic electrodeposition of Cu/Ti B2 electrodeposition rate is the highest, ultrasonic electrodeposition of Cu current efficiency is highest. Ultrasonic composite electroforming grain fine uniform, electric deposition rate and current efficiency is high, less electroforming defects.(3) The aim of this work is to test the electroforming tool electrode machining performance of electrical discharge machining. Ultrasonic electroforming elemental Cu, elemental Cu, electroforming Cu/Ti B2, ultrasonic electroforming Cu/Ti B2, pure copper bar 5 kinds of EDM tool electrode, Nd Fe B work piece processing, according to the work piece removal rate and tool wear rate, the surface roughness of work piece and electrode electrical erosion resistance of the surface quality analysis. Ultrasonic electric cast for Cu/Ti B2 composite electrode machining performance is optimal, reason is that ultrasonic fine grains and Ti B2 particles to strengthen the comprehensive effect of Cu matrix.