Electrochemical Discharge Machining Microstructure By Using Rotary Dentate Disk Amorphous Foil Electrodes

Surface functional microstructures and their processing have become one of the hotspots of international academic research.Surface functional microstructures refer to the microstructures with different shapes,scales,dimensions and functions on the surface of an object.There are many kinds of functions of surface microstructures,including surface adhesion and desorption function,surface thermal function,surface hydrophobic function,surface light function and surface drag reduction function.# 304 stainless steel has excellent corrosion resistance and formability,high specific strength and good heat and corrosion resistance of titanium alloys.They are widely used in aerospace,national defense and other high-tech fields,but the traditional machinability and efficiency of stainless steel and titanium alloys are poor.Electrochemical discharge machining(ECDM)has high efficiency and is not limited by material strength.It is the best choice for processing difficult-to-machine materials such as stainless steel and titanium alloy.In this paper,a rotating ECDM process using dentate disc amorphous thin-film electrodes is proposed to fabricate micro-groove arrays and micro-square arrays on stainless steel and titanium alloys.The experimental data and results are studied.The main contents of this paper are as follows:(1)The application of surface functional microstructures is discussed.The applications of micro groove array and micro square column array and several common processing methods are analyzed and compared.According to the mechanism and research status of ECDM for conductive materials,a rotating ECDM process for teeth disc amorphous thin film electrode is proposed,which combines the advantages of various processing methods;(2)The teeth electrode of amorphous disc was prepared,the rotating ECDM platform was built,the deionized water emulsifier was selected as the processing electrolyte,and the reasonable processing technology and the feed rate of the workpiece were designed to carry out the experimental research;(3)Rotating ECDM micro groove experiment was carried out on stainless steel workpiece by using teeth disc amorphous sheet electrode under different processing methods and process parameters.The effects of processing voltage,electrode speed and processing depth on the opening width,aspect ratio and sidewall slope of micro grooves were studied.Based on the optimized process parameters,the micro-grooves with an opening width of 78 ?m,a depth-width ratio of 6.4 and a sidewall slope of 1.0° degrees were fabricated on stainless steel workpieces,and the micro-groove structure arrays and micro-square column structure arrays were successfully fabricated;(4)Based on the theoretical model of hydrophobic structure and the mechanism of ECDM,the hydrophobic surface functional microstructures were fabricated on Ti-6Al-4V surface by suitable processing technology.The micro-groove arrays with hydrophobic angle 134° degrees and the micro-square column arrays with hydrophobic angle 138° degrees were fabricated successfully.The hydrophobic properties of the prepared titanium alloy microstructures were tested and characterized by experiments.The influence of the geometric parameters of the micro groove structure array and the micro square column structure array on the contact angle and hydrophobic properties of the surface was further clarified.