Removal Mechanism And Technical Study For Gas Film Shielding Electrochemical Micro-machining

The non-smooth surface on the metal can improve the performance of the products,such as heat resistant,smooth friction performance,corrosion protection,bearing capacity,etc.It is expected to be widely used in agricultural machinery,aerospace,mechanical engineering and other fields.In order to realize the manufacture of micro structure on metal with high efficiency and precision,based on the principle of electrochemical micromachining(EMM)technology and air-shielding theory,a new micro-machining method,air-shielding EMM(AS-EMM),was presented.The main research contents and result are as follows:(1)On the basis of studying the principle of electrochemical machining technology,the removal mechanism of AS-EMM was studied.The Superiority of AS-EMM over EMM is explained by the material removal mechanism form the aspects of anode polarization,hydraulic jump,the distribution of gap bubble.The above conclusions are proved by analysis the surface elements and the microscopic surface.(2)The finite element method was applied to simulate the flow field between the cathode and anode in AS-EMM.The simulation results,which explained the Superiority of AS-EMM over EJM from the flow field,show that electrolyte bundle were focus on machining gap and velocity of electrolyte was increased.(3)In preparation for AS-EMM machining experiment,the experimental system was set up and micro shaped electrode was fabricated.The experimental results show that AS-EMM is propitious to decrease surface roughness by 52.5%,reduce the diameter by 63.3%,increase the depth to diameter ratio(DDR)by 35.2%,and reduce the stray corrosion when compared with EMM with the same parameters,verifying the superiority of the new method and processing some diameter of 170?m micro pits.Through the analysis of the results of orthogonal experiment,the micro pit structure with a depth to diameter ratio of 0.226 and a roughness of 0.071?m is obtained through the optimization analysisThe research shows that the advantages of AS-EMM in micro structure machining of metal surface,which can provide reference for related research fields,and help to the promotion of micro structure processing application in industrial areas for further development.