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Turning-form electrode in ultrasonic-aided electrochemical finishing

Pa P. S.

Journal of Achievements in Materials and Manufacturing Engineering

2007

Vol. 21, nr 2

77-80

Purpose: The ultrasonic-aided electrochemical finishing following traditional turning by a turning-form electrode for several die materials is demonstrated. Design/methodology/approach: A guide line for the design process is followed a scientific method including the design requirement, design development, detail design, and experimental analysis is adopted in the current study. The proposed design of turning-form electrode combined with the ultrasonic-aided electrochemical finishing is presented. Findings: Smaller end radius and smaller declination angle are associated with higher current density and provides larger discharge space and better polishing effect. The plate-shape electrode with small end radius and decreasing the surface area of top-view performs the best. The ultrasonic assistance can avoid the difficulty of dreg discharge in the electrochemical finishing, thus increasing the finishing effect. Research limitations/implications: The potential for electrode design and using ultrasonic energy transmitted to the electrolyte to assist discharging dregs out of electrode gap during the electrochemical finishing is yet to be explored. Practical implications: This process can be used for various turning operations including end turning, form turning, and flute and thread cutting. Through simple equipment attachement, the electrochemical finishing can follow the cutting on the same machine and chuck. Originality/value: It is great contribution that the ultrasonic-aided electrochemical finishing after turning process just needs quite short time than manual or machine finishing to make the surface of workpiece smooth and bright. An effective and low-cost finishing method after turning process is presented.