Abstract
In the former research, the ultrasonic vibration technique had been adopted in the electrochemical micro drilling to exclude the reaction products in the inter-electrode gap, while the ultrasonic cavitation phenomenon generates micro jet with strong impulse force, which impacts the insulation coating and speeds up the damage of the insulation coating. In order to improve the service life of the sidewall-insulated electrode, the double insulating layers that consist of TiO2 ceramic coating and organic film were fabricated on the micro titanium electrode surface combining the micro-arc oxidation and electrophoresis coating techniques. The durability of the double insulating layers on the electrode sidewall was verified, and the influence of the ultrasonic vibration amplitude, machining voltage and electrolyte concentration on the machining accuracy with the sidewall-insulated electrode was analyzed through ultrasonically assisted electrochemical micro drilling experiments. The experimental results showed that the double insulating layers exhibited a strong durability in ultrasonically assisted electrochemical micro drilling. The machining was stable when the vibration amplitude of the workpiece was beyond a certain value; henceforth, the machining accuracy changed little with the increase in the vibration amplitude. The straightness of the hole can be effectively ensured, but the machining voltage and the electrolyte concentration should be lowered in order to reduce the overcut in the premise of stable machining.
Published Version
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