304 Stainless Steel Foil Vibration Assisted Wire Electrochemical Micro Machining

Wire electrochemical machining(WECM)is a new micro-processing technology,which uses a metal wire as the tool of the cathode electrode, the metal material as a workpiece anode for a new process of electrochemical machining forming. Processing principle is the metal wire gradually close to the metal material and at the microscopic level the voltage electric is established between two poles, then the surface of the workpiece loses electrons and becomes ions into the electrolyte, and at the macroscopic level the metal material in the electrolyte occurs anode dissolution to achieve the purpose of material removal. Compare with traditional mechanical forming technology, this new molding technology has some advantages. First of all, in the process, the metal wire doesn't contact with the workpiece, and there is no mechanical force, so the metal wire won't be distorted or out of shape in order to reuse.Secondly, from the perspective of precision, WECM uses the micrometer scale wire electrode, which has high precision machining, and it can be used for processing more complicated microstructure. The main contents of this dissertation include the following sections:(1) Designed the fixture to meet the requirements for the characteristics of the WECM, and the wire is not only fixed and tense but ensure a smooth rinse in the machining area.(2) Built a WECM experiment platform. Designed for the movement system,piezoelectric ceramics vibration system, and electrolyte circulation system of the experiment. According to analysis of the process of short-circuit phenomenon, and we also designed the Axial wire electrode micro-vibration system and wire electrodes slightly reciprocating wire system, promoted the discharge of products of electrolysis,to reduce the short circuit phenomenon, and improve the processing stability and precision.(3) Did experiments and researches on the wire electrochemical micro machining.Through the experiments of electrode projection processing, analyzed the feed speed,machining voltage, electrolyte concentration, the range of the wire winding reciprocating, micro-vibration frequency and amplitude and other influence and regularity on the process parameters. Summarized the main factor which impacted the machining precision and stability, and get a set of optimal parameter data, so that the precision of the WECM can be guaranteed at the same time, and the process is more stable.(4) Making three-dimensional superposition electrodes by using of the wire electrochemical micro machining technology and slip resistance welding process combinations. Firstly, processing each electrolytic wire layer which is needed by using of the wire electrochemical micro machining technology. Secondly, welding the superposition electrodes by using of DC inverter spot welding equipment. Finally,taking the prepared three-dimensional superposition electrodes to process by Electrolytic micromachining to obtain the desired microcavity.