Coupling Mechanisms of Electrolytic in Process Dressing-ultrasonic Honing System by Multiphisics Code

Abstract

The electrolytic in process dressing(ELID)-ultrasonic honing system is presented. Fluid-ultrasonic coupling mechanisms of electrolyte between electrodes are simulated by multiphisics code. And comparative experimental study on common honing, ultrasonic honing and ELID-ultrasonic honing is proposed. Simulation results show that the coupling velocity of electrolyte of ELID-ultrasonic honing system increases little with increasing ultrasonic frequency, but the local velocity of electrolyte has dramatic changed. Therefore electrolyte updates velocity increases in the vicinity of the electrodes, and reactive ion transfer process increases in electric double layer, and ion concentration updates velocity and electrode reaction process increases. The coupling pressure has dramatic changed, so the electrolyte updates velocity further increases. And multifrequency simulation results show, better coupling effect can be obtained when ultrasonic frequency in 20-25 kHz. At one time point out, the coupling effect is better when the electrolytic pulse frequency coincides with the ultrasonic frequency. The common honing, ultrasonic honing and ELID-ultrasonic honing ZrO2 ceramics are proposed by the electrolytic parameters, ultrasonic parameters and honing parameters, which obtained from the multifrequency simulation. The experimental results show that the ELID-ultrasonic honing precision is 0.5 μm, ultrasonic honing precision is 1.0 μm and common honing precision is 5.0 μm. The honing precision of ELID-ultrasonic honing system is higher 9 times than common honing technology, and higher 1 times than ultrasonic honing technology. Because of using new acoustics system in ELID-ultrasonic honing system, therefore the amplitude is decreased, so processing efficiency increases little with the same technological parameters. The ELID-ultrasonic honing system is suitable for ultraprecision honing of difficult to machining materials.