Ultrasonic Vibration-assisted Wire Electrochemical Micromachining Technology

With the rapid development of the internet industry and artificial intelligence technology,the trend of miniaturization,integration and intelligence of products in various fields is becoming increasingly obvious.The application of micromachining technology to fabricate high precision microstructures with good surface presents unprecedented challenges.In electrochemical micromachining technology,the updating of electrolyte in the machining area is the key factor to improve the machining quality.In this thesis,Ultrasonic Vibration-assisted Wire Electrochemical Micromachining was put forward.With unique machining method and advantages,ultrasonic vibration was used to solve the mass transfer problem in extremely narrow machining gap,aiming to optimize the machining environment and improve the machining precision and surface quality.The main research content is as follows:(1)The mechanism of Ultrasonic Vibration-assisted Wire Electrochemical Micromachining was studied.The mathematical model of high frequency pulse electrochemical micromachining was established.The influence of ultrasonic vibration on the velocity and pressure of the flow field in the machining gap was analyzed by finite element simulation.(2)The spiral electrode electrochemical micromachining test was carried out.The ultrasonic vibration assisted electrochemical micromachining platform was designed.By means of orthogonal test and single factor comparison test,the influence law of each machining parameter on machining quality was studied,and the law curve was drawn.Comparing the two machining conditions with and without ultrasonic vibration,the optimization effect of ultrasonic vibration on electrochemical machining was verified.By selecting proper ultrasonic vibration amplitude and optimizing machining parameters,the machining of many fine parts and micro connectors has been completed.The machining precision and surface quality were improved,which highlights the machining ability of ultrasonic vibration assisted electrochemical micromachining(3)The wire electrode electrochemical micromachining test was carried out Two kinds of ultrasonic vibration assisted schemes involve workpiece vibration and tool vibration were put forward,and the influence of ultrasonic amplitude on machining precision and surface quality was studied.It was proved that the machining quality of workpiece vibration is better than that of tool electrode vibration through the analysis of test process.The appropriate ultrasonic vibration assisted scheme was selected,and the machining parameters were optimized.Finally,the array micro-gap and the micro-gap with a high aspect ratio were successfully processed.The micro-gear with a small modulus was machined with high machining precision and good surface quality.(4)The application of Ultrasonic Vibration-assisted Wire Electrochemical Micromachining was studied.This technology was applied to the cutting of porous metal materials and the machining of thin-wall tube electrodes.Compared with other machining technologies,its superiority is shown in the field of non-traditional machining,which accelerate its industrialization process.