Abstract
An effective ultrasonic-aided electropolishing system using low-cost electrodes for polishing cylindrical parts is developed. The process can be integrated with the primary processes of traditional turning, drawing, form rolling, or extrusion to achieve a good surface finish for moulds. Ultrasonic energy is applied to the electrolyte for residue discharge during electropolishing. Both continuous and pulsed direct current are tested in the study. The controlled factors include the chemical composition and concentration of the electrolyte, the electrolyte temperature, the flowrate of electrolyte, the initial gap width, and the rotational speed of the workpiece. The experimental parameters are the frequency and power of the ultrasonic vibration, electrical current density, pulse period, rotational speed of the electrode, the electrode feedrate, and the electrode geometry. The incorporation of ultrasonics is found to be more effective than the use of pulsed current, without sacrificing the polishing time. An average surface roughness of 0.3 μm can be obtained by this method.
Published Version
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