Research On Multi-wire And Multi-layer Stacked Workpieces Electrochemical Micromachining

Based on electrochemical anode dissolution,wire electrochemical micromachining(WEMM)is a machining technology which uses a micro-wire as the cathode to process the anodic workpiece combined with two-dimentional plane motion.To solve the problem of low efficiency of WEMM,this paper proposes a multi-wire and multi-layer stacked workpieces electrochemical micromachining(MWEMM)technology.MWEMM uses multiple parallel-arranged wires to process multi-layer equally-spaced workpieces.Simultaneously with the processing,axial reciprocating motion of wires and lateral flushing are performed to promote the discharge of electrolysis products and the renewal of the electrolyte,thereby improving the processing efficiency of WEMM.For this processing technology,the following researches are carried out in this paper.1.A processing method of MWEMM was proposed,the processing principle of MWEMM was analyzed and the characteristics of MWEMM were introduced.Simultaneously,a circuit model of MWEMM was established.The mass transfer path of it in hydrostatic environment was studied.2.The processing test system of MWEMM was improved.The anode and cathode fixture,lateral flushing system and electrolyte circulation filtration system were designed.According to the test requirements,the test monitoring system were designed.The auxiliary devices were designed to improve the test machining accuracy.3.The flow-field characteristics of MWEMM were studied by flow-field simulation when the wire electrode reciprocates.A scheme for mass transfer between the lateral flushing electrolyte and axial reciprocating motion of wires was established.The workpiece spacing is optimized to ensure the consistency of the flow field between the layers of the multil-ayer workpieces by the research of flow-field simulation.Through the electric-field simulation of MWEMM,it was proved that the current density distribution in each processing area of multi-layer workpieces is basically the same,which meets the processing requirements of this method.4.The experimental researches on MWEMM process were carried out.The influence of electrodes feedrate,electrical parameters,electrolyte concentration,electrolyte inlet velocity,frequency and amplitude of wire electrode reciprocating motion on the width and uniformity of the slit was studied,and the processing parameters were optimized.The optimized processing parameters were used to complete the processing of typical structures,and the total processing speed reached 9.6?m / s.