Design of Freeform Surface Finish Using Synchronous Processes of Electrochemical Finishing and Burnishing
A most effective design system and an advantage of low cost equipment using synchronous processes of electrochemical finishing and burnishing for a freeform surface following turning machining is investigated. The proposed design process uses a feeding finish-tool instead of the mate electrode as in conventional ECM. Hence higher electrical current is not required when the effective design electrode is used to reduce the response area. Through simple equipment attachment, electrochemical finishing can follow the traditional turning on the same machine. The controlled factors include the chemical composition and concentration of the electrolyte, die material, and rotational speed of workpiece. The design finish-tool is primarily discussed among the factors affecting the synchronous processes of electrochemical finishing and burnishing. The experimental parameters are initial gap width, flow rate of electrolyte, current rating, feed rate of finish tool, pulsed period, and the evaluation of different process features. The use of large electrolytic flow rate is advantageous to the finish effect. High rotational speed of the finish tool produces better finish. The finish effect is better with longer off-time because discharge of finish dregs becomes easier. Higher current rating with quicker feed rate of finish tool effectively reaches the fast improvement of the surface roughness of the workpiece is recommend in current study. The effective design finish-tool with an electrode of a globe-form and a burnishing tool of a pin-form have an optimal value for higher current density and provides larger discharge space, which produces a smoother surface. The synchronous processes of electrochemical finishing and burnishing just needs only a short time to make the workpiece smooth and bright and saves the need for the precise process of traditional machining is recommended for the finish process of the freeform surface.
Yingxue Yao, Xipeng Xu and Dunwen Zuo
P. S. Pa, "Design of Freeform Surface Finish Using Synchronous Processes of Electrochemical Finishing and Burnishing ", Key Engineering Materials, Vols. 375-376, pp. 308-312, 2008