Research On Wire Electrochemical Machining Of Stacked Workpieces

Wire electrochemical micromachining(WEMM)is a micro machining method using microscale wire as the cathode to process workpiece by anodic electrochemical dissolution.Aiming at solving the problem of low efficiency of wire electrochemical micromachining,this paper proposes a wire electrochemical machining method of stacked workpieces,in which stacked workpiece are cut by the wire electrode at the same time.The following research has been carried out:1.The processing method of stacked workpiece by wire electrochemical machining has been proposed.The principle and characteristic was introduced and its circuit model was established.Besides,the flow field and electric field simulation of wire electrochemical machining of stacked workpiece were carried out.2.The experimental system was developed.The relevant fixture was designed and a microrotating platform with two degrees of freedom was built to ensure the parallelism of wire electrode and Z axis.In addition,the motion control system,monitoring systems,electrolyte systems and so on were designed and built.3.The 200?m-thick 3J53 permanent-elastic alloy was machined by WEMM using a nanosecond pulse power supply.The influence of electrical parameters,electrolyte concentration and feed rate on the width of the machined kerf was studied.Finally,a high-quality machining kerf with a side gap of 4?m was obtained.Through the experiments,it is also found that WEMM of workpiece of more layers is limited by the output power of the nano-second pulse power supply.4.Using a high-frequency narrow pulsed power supply,stacked 3J53 permanent-elastic alloy of 200?m-thick was machined by WEMM.The influence of electrical parameters,electrolyte concentration and feed rate on the processing of four-layer 3J53 permanent-elastic alloy was studied.5.The optimized parameters were used to fabricate the typical structures on stacked workpiece by WEMM,in which process the processing speed reached 3.2?m/s,compared with the single-layer workpiece electrolytic wire cutting,the maximum processing speed is 0.9?m/s,which improves the processing efficiency.The splitter was also processed.In addition,based on the previous studies,the experiments of the multi-wire electrochemical micromachining of stacked workpiece were carried out and various typical structures was machined,in which process the total processing speed reached 7.2?m/s.Further improve processing efficiency.