Abstract
Radial ultrasonic rolling electrochemical micromachining (RUR-EMM) is a new method of electrochemical machining (ECM). By feeding small and rotating electrodes aided by ultrasonic rolling, an array of pits can be manufactured, which is called microstructures. However, there still exists the problem of choosing the optimal machining parameters to realize the workpiece machining with high quality and high efficiency. In the present study, response surface methodology (RSM) was proposed to optimize the machining parameters. Firstly, the performance criteria of the RUR-EMM are measured through investigating the effect of working parameters, such as applied voltage, electrode rotation speed, pulse frequency and interelectrode gap (IEG), on material removal amount (MRA) and surface roughness (Ra). Then, the experimental results are statistically analyzed and modeled through RSM. The regression model adequacies are checked using the analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated and verified by experiment to maximize MRA and minimize Ra. The results show that each parameter has a similar and non-linear influence on the MRA and Ra. Specifically, with the increase of each parameter, MRA increases first and decreases when the parameters reach a certain value. On the contrary, Ra decreases first and then increases. Under the combined effect of these parameters, the productivity is improved. The experimental value of MRA and Ra is 0.06006 mm2 and 51.1 nm, which were 0.8% and 2.4% different from the predicted values.
Highlights
The special properties of microstructures, such as drag reduction and noise reduction [1,2], material surface self-cleaning [3], self-repairing [4], antifriction [5], antifatigue [6] and improving load bearing [7], are expected to be widely used in engineering fields such as agricultural machinery, aerospace, mechanical engineering and so on
Compared with electrical discharge machining (EDM), laser machining, mechanical machining, etc. [8,9,10], electrochemical machining (ECM), which is widely used in the machining of metal surface microstructure [11,12,13], has the advantages of no loss of processing electrode, no residual stress on the surface after processing, no thermal influence layer, high machining surface quality, etc
Ruszaj et al [14] confirmed that the surface quality of the workpiece using ultrasonic electrochemical machining is better than pulsed electrochemical machining, and the addition of abrasive powder have a further improvement on the surface quality
Summary
The special properties of microstructures, such as drag reduction and noise reduction [1,2], material surface self-cleaning [3], self-repairing [4], antifriction [5], antifatigue [6] and improving load bearing [7], are expected to be widely used in engineering fields such as agricultural machinery, aerospace, mechanical engineering and so on. Using RSM to set the cutting parameters such as the electrolyte concentration, electrolyte flowrate, applied voltage and tool feed rate as the variable and set material removal rate and surface roughness as the response, Senthilkumar et al [22] optimize the ECM process parameters to maximize MRR and minimize Ra. Ei-Taweel et al [23] developed a mathematic model to study the performance criteria of the electrochemical turning process through investigating the effect of working parameters, namely, applied voltage, wire feed rate, wire diameter, work piece rotational speed and overlap distance, on the metal removal rate, surface roughness and roundness error. For RUR-EMM, it is necessary to explore the relationship of machining parameters, such as applied voltage, pulse frequency, electrode rotation velocity and interelectrode gap, and target parameters, such as material removal amount and surface roughness to get an optimal parameter, which is a multivariable and multiresponse problem. The adequacy of the developed theoretical models was tested by an analysis of variance (ANOVA) test
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
