Improving surface integrity of micro-holes in ECDM using ultrahigh-speed rotary of tool cathode and non-water-based electrolyte

Jiwen SHEN ¹Weijing KONG ¹Zhengyang XU ¹Yongbin ZENG¹

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作者信息

1. Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China
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Abstract

The surface integrity of metal micro-hole structures produced by electrochemical dis-charge machining is unsatisfactory owing to the insufficient reaction area and strength of electrol-ysis 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 break-down 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 val-idate 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 2.54 μm to 0.20 μm when the rota-tional speed increases from 500 r/min to 40000 r/min.The length loss and wear ratio of the cathode are only 9.75 μm and 6.5％,respectively.Finally,the micro-holes array with recast-free and surface roughness of 0.20 μm is fabricated,demonstrating that the proposed approach contributes to improving surface integrity of metal micro-holes.

Key words

Electrochemical discharge machining/Micro-holes/Recast layer/Ultrahigh-speed rotary/Bubbles/Force analysis/Non-water-based solution

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基金项目

National Natural Science Foundation of China(91960204)

Natural Science Foundation of Jiangsu Province,China(BK20222010)

National Natural Science Foundation of China for Creative Research Groups(51921003)

Project of Science Center for Gas Turbine Project,China(HT-P2022-B-Ⅳ-010-001)

Fundamental Research Funds for the Central Universities,China(NP2022422)

Experimental Technology Research and Development Project in Nanjing University of Aeronautics and Astronautics,China(SYJS202203Z)

出版年

2024

中国航空学报(英文版)

中国航空学会

中国航空学报(英文版)

CSTPCDEI

影响因子：0.847

ISSN：1000-9361

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