System Design And Experimental Research On Wire Electrochemical Micro-machining Of Ring Groove

The processing of Metal narrow groove is widely used in manufacturing of modern industrial production. The main processing methods of Narrow groove include traditional precision machining, WEDM and laser material processing so on. Those machining processes have their own defects, such as mechanical forces and stresses into the work piece material, electrode wear, surface burning and expensive. Electrochemical machining is an anodic dissolution process of workpiece in a flowing electrolyte where the shape of the tool as cathode is copied into the workpiece as anode with the removal of the anode ion by ion. Due to the tiny size of metal ions, cathode without loss, no mechanical cutting force, high machining efficiency, no residual stress and no heat treatment borne on the workpiece surface and wide materials suit to fabricate, therefore, ECM should be a promising micromachining technique for manufacturing micro parts with dimensions in micrometer order or even in nanometer order.Based on analysis of electrochemical anodic dissolution theory and the characteristics of the micro wire cutting, ECM experimental research of the typical micro scale multi-grooves structure is carried out. The primary research contents of this paper including:1. Considering the characteristics of micro ECM and the difference between rotational body and plate parts, the experimental setup is established. It is mostly consists of four parts which are motion platform of machine、motion control system of machine tool、high frequency narrow-width pulse power supply、electrolyte circulating system、system of flushing mode of electrolyte which flowing along the axis of the wire electrode, is adopted to remove the electrolysis products and renew the electrolyte in the machining gap.2. With the developed micro ECM system, a series of experiments were carried out in stainless steel. First, the forming cutting characteristics of workpiece in the condition of different power types were researched and deliberated to verify the pulse power supply is available. Secondly, effects of several factors, such as the velocity of feed forward、 machining gap、machining voltage、frequency and duty ratio on machining precision were investigated. Finally, optimization parameters were obtained.3. Machining tests of the outer surface groove of the pure tungsten rod were carried out. The polarization curve of pure tungsten was briefly determined so as to provide reference for the pure tungsten cutting mechanism of Metal Electrochemical Wire-cutting technology. The surface ring groove of pure tungsten processing research in the condition of pulse current by using single component electrolyte, pulse current complex electrolyte was carried out. The technological parameter’s effect on machining accuracy and machining efficiency of groove was analyzed through the experimental data. The result shows that complex electrolyte can increase machining precision and efficiency.