Experimental Investigation on Through-mask Electrochemical Machining of Elliptical Micro-dimple Arrays on Titanium Alloy
In order to meet the manufacture demands of textured flow channels in ion thruster,experimental research on through-mask electrochemical machining(TMECM)of elliptical micro-dimple arrays on titanium alloy TC4 was carried out.Through simulations on electric field,it was found that as machining goes on,the micro-dimple gradually changes from rectangular to elliptical and eventually to approximately circular,and the increment of micro-dimple in the short axis direction of the ellipse is greater than that in the long axis direction.An auxiliary support compression device was designed to inhibit the stray corrosion of the non-machined surface,and the influence of machining time and duty cycle on the dimple size was studied.The study showed that under the optimal conditions of processing voltage of 30 V,frequency of 2 kHz,time of 60 s and duty cycle of 8%,the elliptical micro-dimple arrays were efficiently and consistently processed with an average depth of 98.04 μm,and the average long axis width and short axis width is 198.25 μm and 186.84 μm.
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