Electrochemical machining （ECM） has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is...Electrochemical machining （ECM） has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is to a great extent limited by the stray corrosion of the unwanted material removal. Many attempts have been made to improve the ECM accuracy, such as the use of a pulse power, passivating electrolytes and auxiliary electrodes. However, they are sometimes insufficient for the reduction of the stray removal and have their limitations in many cases. To solve the stray corrosion problem in CRECM, insulating and conductive coatings are respectively used. The different implement processes of the two kinds of coatings are introduced. The effects of the two kinds of shielding coatings on the anode shaping process are investigated. Numerical simulations and experiments are conducted for the comparison of the two coatings. The simulation and experimental results show that both the two kinds of coatings are valid for the reduction of stray corrosion on the top surface of the convex structure. However, for insulating coating, the convex sidewall becomes concave when the height of the convex structure is over 1.26 ram. In addition, it is easy to peel off by the high-speed electrolyte. In contrast, the conductive coating has a strong adhesion, and can be well reserved during the whole machining process. The convex structure fabricated by using a conductive iron coating layer presents a favorable sidewall profile. It is concluded that the conductive coating is more effective for the improvement of the machining quality in CRECM. The proposed shielding coatings can also be employed to reduce the stray corrosion in other schemes of ECM.展开更多
In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpi...In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.展开更多
A new mechanical electrodeposition technology was proposed, and nanocrystalline nickel deposit with bright and smooth surface was prepared in the bath without any additive agents. Unlike traditional methods, the novel...A new mechanical electrodeposition technology was proposed, and nanocrystalline nickel deposit with bright and smooth surface was prepared in the bath without any additive agents. Unlike traditional methods, the novel technology employed dynamical hard particles to continuously polish the cathode surface and disturb the nearby solution during electrodepositing. Experimental results showed that the polishing effect of hard particles can effectively prevent the hydrogen bubbles and impurities from adhering on the deposit surface and avoid the production of pits, pinholes and nodules. Furthermore, comparing with the deposit prepared by traditional methods, the one prepared by the novel technology was substantially refined with grain size ranging from 30 to 80 nm. Every diffraction peak's intensity of the deposit was reduced, the preferential orientation degree of (200) decreased and those of (111) and (220) increased. The microhardness notably increased. The magnetic properties were also changed with decreased saturation magnetization and increased coercive force. It was also found that variation of current density and cathode rotational speed could affect the structure and properties of the nickel deposits prepared by this technology.展开更多
A cathode mandrel with translational and rotational motion, which was supposed to obtain uniform friction effect on surface, was employed in abrasive-assisted electroforming for revolving parts with complex profile. T...A cathode mandrel with translational and rotational motion, which was supposed to obtain uniform friction effect on surface, was employed in abrasive-assisted electroforming for revolving parts with complex profile. The effects of current density, translational speed and rotational speed on the deposit properties were studied by orthogonal test. The tensile strength,elongation and micro hardness value were measured to find out how the factors affected the properties. The optimized results show that changes of current density affect the tensile strength of nickel layer most, while translational speed has the most remarkable influences on both elongation and micro hardness. The low rotational speed affects the properties least. In this experiment, a smooth nickel layer with tensile strength 581 MPa, elongation 17% and micro hardness 248 HV is obtained by the orthogonal test.展开更多
基金Supported by Program for New Century Excellent Talents in University,China(Grant No.10-0074)
文摘Electrochemical machining （ECM） has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is to a great extent limited by the stray corrosion of the unwanted material removal. Many attempts have been made to improve the ECM accuracy, such as the use of a pulse power, passivating electrolytes and auxiliary electrodes. However, they are sometimes insufficient for the reduction of the stray removal and have their limitations in many cases. To solve the stray corrosion problem in CRECM, insulating and conductive coatings are respectively used. The different implement processes of the two kinds of coatings are introduced. The effects of the two kinds of shielding coatings on the anode shaping process are investigated. Numerical simulations and experiments are conducted for the comparison of the two coatings. The simulation and experimental results show that both the two kinds of coatings are valid for the reduction of stray corrosion on the top surface of the convex structure. However, for insulating coating, the convex sidewall becomes concave when the height of the convex structure is over 1.26 ram. In addition, it is easy to peel off by the high-speed electrolyte. In contrast, the conductive coating has a strong adhesion, and can be well reserved during the whole machining process. The convex structure fabricated by using a conductive iron coating layer presents a favorable sidewall profile. It is concluded that the conductive coating is more effective for the improvement of the machining quality in CRECM. The proposed shielding coatings can also be employed to reduce the stray corrosion in other schemes of ECM.
基金supported by the Program for New Century Excellent Talents in University of China(NCET-10-0074)
文摘In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.
基金the Natural Science Foundation of Jiangsu Province, China (Grant No. BK2004005)
文摘A new mechanical electrodeposition technology was proposed, and nanocrystalline nickel deposit with bright and smooth surface was prepared in the bath without any additive agents. Unlike traditional methods, the novel technology employed dynamical hard particles to continuously polish the cathode surface and disturb the nearby solution during electrodepositing. Experimental results showed that the polishing effect of hard particles can effectively prevent the hydrogen bubbles and impurities from adhering on the deposit surface and avoid the production of pits, pinholes and nodules. Furthermore, comparing with the deposit prepared by traditional methods, the one prepared by the novel technology was substantially refined with grain size ranging from 30 to 80 nm. Every diffraction peak's intensity of the deposit was reduced, the preferential orientation degree of (200) decreased and those of (111) and (220) increased. The microhardness notably increased. The magnetic properties were also changed with decreased saturation magnetization and increased coercive force. It was also found that variation of current density and cathode rotational speed could affect the structure and properties of the nickel deposits prepared by this technology.
基金financial support from the Program for New Century Excellent Talents in University of China (No. NCET-10-0074)
文摘A cathode mandrel with translational and rotational motion, which was supposed to obtain uniform friction effect on surface, was employed in abrasive-assisted electroforming for revolving parts with complex profile. The effects of current density, translational speed and rotational speed on the deposit properties were studied by orthogonal test. The tensile strength,elongation and micro hardness value were measured to find out how the factors affected the properties. The optimized results show that changes of current density affect the tensile strength of nickel layer most, while translational speed has the most remarkable influences on both elongation and micro hardness. The low rotational speed affects the properties least. In this experiment, a smooth nickel layer with tensile strength 581 MPa, elongation 17% and micro hardness 248 HV is obtained by the orthogonal test.
