| Wire electrochemical machining(WECM) is a new derivation of electrochemical machining(ECM), in which process the metal wire is utilized as the cathode tool while the conductive workpiece is removed by anodic dissolutions. In this paper, multi-wire electrochemical machining with reciprocated traveling wire has been proposed in order to enhance the rate of removing reaction products away from the narrow inter-electrode gap during the machining process and to improve the machining efficiency. The multiple parallel wire electrode, which is formed by twining a metal wire on the guide roller with multiple parallel grooves, has been introduced to WECM. To study the characteristics of multi-wire electrochemical machining, following research has been done.1. The multi-wire electrochemical machining with reciprocated traveling wire electrode has been proposed, and the principle and characteristics of the proposed processing method were analyzed in detail. Additionally, the distribution of the flow field during the machining process has been studied.2. The experimental system for multi-wire electrochemical machining has been developed, including the multi-wire traveling system, high precision three-dimensional motion platform, electrolyte circulating system, power system, and process monitoring system.3. Experiments have been conducted to investigate the influences of the number of wires on machining gap, machining stability and processing efficiency of multi-wire electrochemical machining. Moreover, a series of experiments were also carried out to investigate the effects of various parameters on the average slit width, such as wire travel speed, electrolyte concentration, pulse voltage, pulse duty ratio, pulse frequency, and workpiece feeding rate. The optimal processing parameters have been obtained.4. By using the optimized processing parameters, the typical array structures have been successfully fabricated with the total feeding rate of the workpiece up to13?m/s. |
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