Study On The Influence Of The Mechanical Action And The Replication Effect On The Surface Characteristic In Electrochemical Mechanical Finishing

A variety of micro physical behaviors produced by the degree of regularization and the morphology characteristics of the surface micro geometric profile,those shows different performance on the macro level.As a surface modification technology,electrochemical mechanical finishing(ECMF)combined the mechanical action and electrochemical anodic dissolution to remove the materials and change the micro morphology distribution.The formation and distribution of the surface micro geometric profile is affected by many processing parameters.In this paper,the effect and mechanism of different processing parameters changed the micro geometric profile of workpiece surface and the distribution characteristics of the surface micro geometry are studied by finite element analysis and experiment.1.In order to study the influence of the replication effect on the surface profile of anode.Under the basis of the ECMF model,different machining methods were used to formed the arc and peak micro geometric profiles on cathode surface.Through the analysis of different fields,such as the current field and temperature field,the influence of the replication effect of the two kinds of cathode morphology on the anode surface was compared.The results show that under the condition of small machining gap,the formation of anode surface micro geometry was completed by the combination of the replication effect of cathode and the effect of electrochemical anode dissolution.With the increased of the micro geometry height of cathode surface,the replication effect to the anode surface has enhanced and the machining efficiency has improved in the same time.The arc micro geometric profile improved the anode surface quality was better than the peak micro geometric profile cathode surface.The anode surface produced by the arc micro geometric profile was more sensitive to heat flux.Different cathode surface heights has a smaller effect to the sensitivity of anode surface node temperature.2.In order to study the effect of mechanical action and passive film thickness on the surface micro profile of anode.Through the ECMF model,the influence of mechanical action and the thickness of passive film to the anode surface was simulated and analyzed.Combined with the simulation conclusion,the processing parameters of ECMF were optimized.It was used to verified whether the surface could have a good service performance after optimized.The results show that when the mechanical action was larger,the ECM reaction was accelerated,the machining efficiency was improved and the flow field environment was better too.With the increased of mechanical action,the heat flux on the anode surface and the temperature of the node was increased rapidly and then decreased slowly.For passive film,the percentage increased in a certain range,the current density shown a downward trend,the efficiency of finishing was decreased gradually,the phenomenon of stray corrosion was also intensified,which has a negative impact on the surface quality.At different electrolyte percentage,the heat flux in the processing area was decreased slowly and then increased rapidly,while the node temperature was continued to increase.Under the condition of the same original surface quality,the micro geometry of the anode surface which produced by ECMF that optimized mechanical action and electrolyte percentage has a stronger dynamic pressure effect than that of the surface which produced by grinding,it also reduced the sensitivity of the pressure field fluctuation and achieved the improvement of the performance of drag reduction,wear resistance and vibration reduction.3.The fractal theory was used to reconstruct the specimen surfaces.Combined with the fractal parameters and surface parameters,the distribution characteristics of surface micro geometry were analyzed,the conclusions which obtained early were verified in the same time.