Experimental Research On Microstructure Surface Of Electrolytically Processed By Scanning Jet Mask

Surface microstructure plays an important role in many fields such as heat conduction,friction and wear,fluid dynamics,chemical reaction characteristics,etc.How to process surface microstructure efficiently and with high quality has become an important research hotspot.At present,the surface microstructure machining technology mainly includes mechanical machining,laser machining,abrasive gas jet processing,Electrical discharge machining and electrolytic machining.Among them,the electrolytic machining is to remove materials in the form of ions.During the machining,the advantages of no stress and heat-affected zone generation,and no tool loss are easy to realize the machining of fine structures.Therefore,electrolytic machining has a unique advantage in surface microstructure manufacturing.In order to produce micro-pits and micro-grooves on the metal surface,on the basis of an in-depth investigation of the research status of the surface microstructure of the mask electrolytically machined at home and abroad,a new method for the electrolytic machining of surface microstructures by scanning jet masks is proposed.The main research contents of this article are as follows:(1)Based on the COMSOL multi-physics field,the electric field and forming process of the jet mask electrolytic machining are simulated and analyzed.Electric field simulation was carried out on the micro-pits with single-hole mask diameter(2-200μm),and the relationship between the size of the mask aperture and the electric field was studied.At the same time,the numerical simulation of the formation process of the micro pits was carried out,and the influence of different mask apertures on the size and morphology of the micro pits was studied,which laid the foundation for the subsequent electrolytic machining experiments.(2)Conducted the experimental research on the scanning jet mask electrolytic machining of micro-pits.A scanning jet electrolytic machining system was built,an experimental fixture was designed,and an experimental plan was planned.Electrolysis machining experiments with different mask apertures(2-300μm)were completed and compared with simulation results.A single factor experiment was conducted to study the influence of processing gap,pulse electrical parameters and scanning parameters on the processing of micro-pit arrays.Orthogonal experiments were carried out,and the primary and secondary relationship of various factors on the processing of micro-pits was determined by range analysis.The processing parameters were optimized,and a micro-pit array structure with an average diameter and depth of 7.56μm and 3.39μm was processed using a mask hole with a diameter of 2μm,which realized the efficient and high-precision processing of the micro-pit array.(3)Carried out the experimental research on the scanning jet mask electrolytic machining micro-groove structure technology.The micro-groove forming process was studied,the dimensional accuracy of different positions of a single groove was analyzed,the dimensional deviation of the groove was studied,and the cause of the deviation was explored through comparative experiments.The experimental parameters were optimized,the micro-groove array structure with good size consistency was processed,and the influence of the scanning direction on the size of the micro-groove array was explored.The effect of scanning jet mask electrolytic machining on the cross-groove morphology was studied.The results show that islanding is prone to occur at the intersection of grooves.Prolonging the processing time or increasing the current density can effectively eliminate islands.Finally,the graphic microstructure was tested and processed,and good processing results were obtained.