Investigation of the ignition phase in electrolytic plasma polishing under different starting conditions

Abstract

Electrolytic plasma polishing is a hybrid process in which the electrolytic process is an assisting process for a plasma region, which subsequently cleans and polishes the surface of a workpiece. The basic process takes place in an electrolyte bath, where very different starting conditions can be met. The extreme cases are the ignition in the bath, the ignition during a rapid immersion phase and the ignition in a slow immersion phase. Characteristic of these individual cases are the extreme changes of the tool impedance in connection with the electrolyte. The paper shows how the current-voltage characteristic can be measured, without adjustment problems between the process energy source (PES) and the connection impedance. The individual phases of the ignition phase are explained on the basis of a phenomenological model and the changes in the model (equivalent circuit diagram) of the process are taken into account. From these findings, the conditions can be derived to the PES and energy consumption in the ignition phase can be minimized. The basic objective is also to convert the ignition phase into a stable polishing phase and to have as few re-ignition phases as possible during the polishing period. In particular, the boundary conditions for the Bath-PeP are defined, which allow for a fast polishing of the surface, without deteriorating the mechanical properties of the surface or changing the geometry of the functional surface. In contrast to electrolytic polishing, no edge rounding occurs if a correspondingly short processing time is maintained.