Rolling-Leveling Assistance in Ultrasonic Electrochemical Finishing of External Cylindrical Surface

Abstract

A new tool product consists of an effective electrode and a nonconductive roller utilizing rolling-leveling assistance in ultrasonic electrochemical finishing, as a continuous surface finishing process following turning is investigated. Through a simple equipment attachment, ultrasonic electrochemical finishing and rolling-leveling can follow to execute the finishing process on the same machine. The submitted processes may be used for various turning operations. Among the factors affecting rolling-leveling combined with the ultrasonic electrochemical finishing, the performance of the design tool product is primarily discussed. In the experiment, the electrode is used with a continuous and a pulsed direct current. The experimental parameters are frequency and power level of ultrasonics, die material, electrical current rating, feed rate of tool electrode and roller, rotational speed of the workpiece, pulsed period, and tool geometry. A higher workpiece rotational speed produces a better finishing result. The design change of the tool from a semicircle to a wedge-form with small end radius brings about a reduction of the electrolytic dregs and heat more rapidly, and performs the best finishing result. The finishing effect of pulsed direct current is slightly better than using continuous direct current. The average effect of the ultrasonics is better than the pulsed current, while the machining time does not need to be prolonged by the off-time. An effective and low-cost finish process through the tool product design utilizing the rolling-leveling assistance in the ultrasonic electrochemical finishing after the turning process make the surface of the workpiece smooth and bright in a shorter period of time.