High Precision Material Removal Of Copper Surface By Jet Electrochemical Machining

Because of its good electrical and thermal conductivity,copper is widely used in precision structural devices in the electronics industry,aerospace,instrumentation,military industry,medical equipment and other fields.Jet electrochemical machining(Jet-ECM)is an important variation of traditional electrochemical machining(ECM).Jet-ECM removes material by jetting electrolyte from the nozzle toward the workpiece while applying voltage on cathode(nozzle)and anode(workpiece).According to literature research,Jet-ECM is suitable for the machining of precision structural devices made of copper.Based on summarizing the research status of traditional precision machining and non-traditional precision machining at home and abroad,a high-precision Jet-ECM system using a new acidic electrolyte was conducted.The electric field distribution of the workpiece surface during the machining process was simulated and analyzed.The effects of process parameters on the removal profile and surface roughness of Jet-ECM were analyzed.Meanwhile,the calculation of the complex structure removal profile was carried out,and the actual machining results were compared.The main research works are as follows:(1)The current research status of precision machining technology and the theory of electrochemical jet processing were discussed.A complete high-precision Jet-ECM system was conducted,including the electrolyte circulation system,the electrolyte jet components,the motion control components,tool setting device,leveling device and high-frequency pulse power supply.Using T2 copper sheet as anode workpiece material,and a new type of acidic electrolyte based on phosphoric acid for Jet-ECM was proposed.The anodic polarization curve was measured,providing the Jet-ECM with experiment foundation.(2)The electric field distribution of the workpiece surface by Jet-ECM was studied by the method of finite element modeling analysis.The effects of process parameters such as processing time,processing voltage,interelectrode gap(IEG),electrolyte temperature,electrolyte flow rate and duty cycle of pulse power supply on the removal profile and surface roughness were investigated in detail.The removal rule of Jet-ECM based on new phosphoric acid electrolyte was summarized.With comprehensive consideration of the effect of process parameters on the machining performance,optimal parameters of voltage 3.5 V,IEG 500 ?m,electrolyte temperature 45 ?,flow rate 50 mL/min were selected and the removal rate was 9.43 ?m/min.The 3�3 array pits were machined,and the results showed high surface quality(6.81 nm Ra)and high removal stability(the removal depth fluctuation was within 0.3 ?m,the error was about 3.2%).(3)The removal profile calculation of the complex structure and actual machining were carried out.The removal profile analytical derivation of the linear groove and the annular groove were carried out by using the removal profile of the fixed-point machining.The analytical calculation results were compared with the actual machining results,and the results show that Jet-ECM can be used to machining high-precision and complex structures.The removal profile of machining and the removal profile of analytical calculations have good consistency.The linear groove and the annular groove have a depth error within 5%.