Effective form design of electrode in electrochemical smoothing of end turning surface finishing

Abstract

Abstract In the current study, the most effective geometry for the design electrode and the advantage of the low cost equipment in electrochemical smoothing following end turning is investigated. Through simple equipment attachment, electrochemical smoothing can follow the cutting on the same machine. An adequate workpiece rotational speed associated with higher electrode rotation produces better polishing. The effective design electrode with a small wedge angle and a small edge rounding radius have an optimal value for higher current density and provides a larger discharge space, which produces a smoother surface. The electrode of the partial curve with a small line diameter performs the best for the electropolishing. Electrochemical smoothing saves the need for precise turning, making the total process time less than the electrobrightening. But the electrobrightening after precise turning only requires quite a short time to make the workpiece bright. The use of ultrasonics in the electrochemical smoothing and the electrobrightening is more evident than the pulsed current, since the ultrasonics-aided process exempts off time and obtains a better polishing result.