Electrochemical Machining of Deep-Small Holes and Parameter Optimization
Parts with deep micro-hole structures find extensive applications in the fields of aerospace,medical devices and molds.Not only is this structure featured by small pore size and high depth-to-diameter ratio but also demands high-quality pore wall surfaces,posing a challenge in manufacturing.Deep-small holes can be electrochemically machined(ECM)with minimal tool loss,producing great surface quality.If neutral electrolyte is used for processing,electrolytic byproducts will obstruct the drainage channel,impairing the processing stability.Many metrics are employed in this research to examine the machining stability.To solve this problem,an indexλis built in the qualitative analysis.Four experimental parameters-hydraulic pressure,voltage,machining speed,and conductive zone length-are designed for an orthogonal test.The results show that when the voltage is 15 V,the flushing pressure 0.3 MPa,the feed speed 30 m·s-1,and the conductive zone length 0.5 mm,the most stable ECM process is obtained.Under these conditions,a SUS304 workpiece with a diameter of about 1.1 mm,a depth of 200 mm through the hole,and a depth-to-diameter ratio of 181 was successfully machined in neutral electrolyte.The machining process was steady.
deep hole machiningelectrochemical machiningneutral electrolyteorthogonal testprocessing stability
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