Study on Multi-effect Synergy Mechanism of the Ultrasonic Compound Electro-discharged and Electrochemical Machining and Real Time Optimal Controlling of On-line Parameters

Abstract

A micro-fine manufacturing method is proposed, that is the ultrasonic modulating compound synchronous pulse electro-discharged and electrochemical machining, the micro discharge and electrochemical multi-effect synergy machining mechanism is studied, the role of micro-spark discharge could remove the electrolytic passivation film on the anode surface, the ultrasonic vibrating blast wave may remove outcomes and renew the working fluid, the better machining precision can be acquired. Ultrasonic modulating discharge-electrochemical micro-fine machining system is built, the real time machining parameters can be measured and controlled by the machining system, the measuring sensor signals are delivered to the computer by the PCI-1706U synchronous data acquisition card, by the control computer and soft system, the parameters are adjusted in real time, the steady optimization process could be kept. By the real time machining parameters, evaluate the multi-kinds energy, coordinating the energy relation of ultrasound and electrolytic effects, so the machining parameters could be optimized in real time and on line. Ultrasonic compound electro-discharged and electrochemical machining tests are carried for machining piezoelectric ceramic(PZT) and hard alloy(YT15), the real time control manufacturing system works reliable, the processing accuracy can up to ±0.001mm, the surface roughness is Ra 0.08μm. The machining way's feasibility and technical superiority are verified.