The surface integrity of metal micro-hole structures produced by electrochemical discharge machining is unsatisfactory owing to the insufficient reaction area and strength of electrolysis action.A novel ultrahigh-spee...The surface integrity of metal micro-hole structures produced by electrochemical discharge machining is unsatisfactory owing to the insufficient reaction area and strength of electrolysis action.A novel ultrahigh-speed Rotary Electrochemical Discharge Machining(R-ECDM)using non-water-based electrolyte is proposed to improve surface integrity by changing the breakdown medium of spark discharge and increasing the reaction area and strength of electrolysis.A mathematical model was developed to establish the relationship between rotational speed and forces acting on the bubble.Based on the magnitude of forces,controlling rotational speed changed the behavior and departure radius of bubbles on the cathode surface.High-speed photographs validate that,in the mathematical model,the number and departure radius of bubbles on the cathode surface gradually decrease with the increase of rotational speed.The experimental results show that the roughness(Ra)of the micro-hole sidewall decreases from 2.54μm to 0.20μm when the rotational speed increases from 500 r/min to 40000 r/min.The length loss and wear ratio of the cathode are only 9.75μm and 6.5%,respectively.Finally,the micro-holes array with recast-free and surface roughness of 0.20μm is fabricated,demonstrating that the proposed approach contributes to improving surface integrity of metal micro-holes.展开更多
基金The authors acknowledged the financial support provided by the National Natural Science Foundation of China(No.91960204)the Natural Science Foundation of Jiangsu Province,China(No.BK20222010)+3 种基金the National Natural Science Foundation of China for Creative Research Groups(No.51921003)the Project of Science Center for Gas Turbine Project,China(No.HT-P2022-B-IV-010-001)the Fundamental Research Funds for the Central Universities,China(No.NP2022422)the Experimental Technology Research and Development Project in Nanjing University of Aeronautics and Astronautics,China(No.SYJS202203Z).
文摘The surface integrity of metal micro-hole structures produced by electrochemical discharge machining is unsatisfactory owing to the insufficient reaction area and strength of electrolysis action.A novel ultrahigh-speed Rotary Electrochemical Discharge Machining(R-ECDM)using non-water-based electrolyte is proposed to improve surface integrity by changing the breakdown medium of spark discharge and increasing the reaction area and strength of electrolysis.A mathematical model was developed to establish the relationship between rotational speed and forces acting on the bubble.Based on the magnitude of forces,controlling rotational speed changed the behavior and departure radius of bubbles on the cathode surface.High-speed photographs validate that,in the mathematical model,the number and departure radius of bubbles on the cathode surface gradually decrease with the increase of rotational speed.The experimental results show that the roughness(Ra)of the micro-hole sidewall decreases from 2.54μm to 0.20μm when the rotational speed increases from 500 r/min to 40000 r/min.The length loss and wear ratio of the cathode are only 9.75μm and 6.5%,respectively.Finally,the micro-holes array with recast-free and surface roughness of 0.20μm is fabricated,demonstrating that the proposed approach contributes to improving surface integrity of metal micro-holes.
