Pulse Electrochemical Finishing Research Articles

Experiment Study of Pulse Electrochemical Finishing of GCr15 Bearing Steel

The pulse electrochemical finishing (PECF) of GCr15 bearing steel was studied. The effect of the main processing parameters, such as electrolyte concentration, inter-electrode gap, current density, pulse parameters, and processing temperature, on the processed surface quality was discussed. The results indicate that PECF has a good effect on GCr15 bearing steel and has a good application prospect on the finishing of bearing raceways.

Analysis of Electric Field of Pulse Electrochemical Finishing of Shaped Cathode on Gears

Gear’s pulse electrochemical finishing (PECF) technology by shaped electrodes based on the numeral control technology, which controls gear dividing device and feed movement, is put forwards. Based on numerical simulation, electrochemical reaction region is dispersed. According to gear tooth profile and negative electrode surface equations, boundary conditions are inferred. The numerical simulation of the electric potential distribution in the calculation region has been shown. Under the optimized parameters, a mirror-like surface of gear teeth could be gained by PECF. The results show PECF can fulfill the advantages in the finishing some special gears with hard teeth.

Research on Fine and Deep Holes of Pulse Electrochemical Finishing

Top-quality surfaces are obtained by means of pulse electrochemical finishing (PECF) in neutral electrolyte. The rules of effect of main experimental parameters such as pulse current density, electrolyte flow rate and interelectrode gap on surface quality are analyzed based on the experiments in detail. Moreover, the technique are applied to some typical cases such as surface finishing of fine and deep holes that is more difficult to be machined by the traditional finishing technologies. The results show mirror-like surfaces could be gained by PECF and the surface roughness values could be reduced from more than Ra 1.6μm to less than Ra 0.08μm within several seconds. The experiments show that PECF will play an important role in finishing key parts that is more difficult to be machined by the traditional finishing technologies in the modern manufacturing industries.

Mathematical modeling for finishing tooth surfaces of spiral bevel gears using pulse electrochemical dissolution

Gears with a complex curve tooth, such as spiral bevel and hypoid gears, lack an ideal technique for the final finishing process. Pulse electrochemical finishing (PECF) is considered a promising method for surface finishing due to its micro-removal characteristics. A PECF system for spiral bevel gear (SBG) is established according to the generation of SBG tooth surfaces. An SBG (module, 12 mm; number of teeth, 38) is selected as the processing test piece, and mathematical models are developed for analyzing the characteristics of PECF. The influence of the experimental variables, including applied voltage, interelectrode gap, and finishing time, on the total removal thickness and surface roughness is discussed. The calculated values are found to be approximately consistent with the experimental values. The other parameters, including the concentration of electrolyte, tool rotational speed, flow rate of electrolyte, and pulse period, are also studied. Results show that the roughness of the SBG tooth surface is reduced from Rz 7.13 to 4.32 μm. The precision of the SBG is also improved.

Gear Finishing and Modification Compound Process by Pulse Electrochemical Finishing with a Moving Cathode

Gears’ surface quality and modification characteristic have an important influence on its working performance. Pulse Electrochemical Finishing (PECF) could get excellent surface topography. In this project, PECF with a scanning cathode is used to finishing the cylinder gear. Tooth profile modification is realized by PECF with an uneven interelectrode gap distribution along the tooth profile and tooth lead modification is realized by PECF with a variable moving velocity of the cathode. The experimental results show that the tooth surface roughness could be decreased from Ra 3.9μm to Ra 0.35μm, which means that the PECF process possesses the finishing ability for the raw surface tooth, and the difference of material removal of PECF with an uneven interelectrode gap distribution could be 46μm and the material removal could be controlled by regulating the moving velocity of the cathode, which means tooth profile and lead modification could be realized by PECF.

Pulse electrochemical finishing: Modeling and experiment

Surface quality of the workpiece has great influence on its service performance and lifespan. Pulse electrochemical finishing (PECF) provides an effective method for improving surface quality of the workpiece. In PECF, surface irregularities are removed by electrochemical dissolution rather than by cutting force. Due to non-contact nature of the process, there is no residual stress and thermal effect on the workpiece surface. For successful utilization of PECF, in present manufacturing, it still demands for more intensive research, including the mechanism of anodic smoothing. The anodic smoothing characteristics of PECF are analyzed through a developed mathematical model. The main influencing factors such as the finishing time, the interelectrode gap, the applied voltage and the rotational speed of electrode have been examined. The predictive values based on the developed mathematical model are found to be in reasonable agreement with the experimental values. The surface roughness Rz ranges from 3 μm to 1.22 μm. The research achievement through various parametric studies can be used as a guideline for the operation of a PECF system.

Design of UAPEF Super Finish Module on ZDC2 Surface

A new fabrication module to help dregs discharge on a free-form surface as a super finish module is demonstrated using an effective design mechanism and ultrasonic energy sent to the electrolyte. The proposed process increases the performance of the pulsed-electrochemical finishing. The outer shell of a toy plane was used as a workpiece sample in the current experiment. Four types of design electrodes were used and supplied with both continuous and direct pulsed current in the experiment. The design features of the manufacturing mechanism using pulse-electrochemical finishing with ultrasonic assistance (UAPEF) are of major interest. An electrode with a small end radius is associated with higher current density, and provides larger discharge space and better finish. However, the pin-type electrode provides the largest discharge space and performs the best among the discussed electrodes. The super finish of UAPEF after die casting saves the need for hand or machine polishing and requires a shorter time to make the casting surfaces smooth and bright. An effective and low-cost super finish module for the freeform surface of castings that use satisfactory electrode geometry and ultrasonic assistance is presented. The proposed ultrasonic assistance has proven effective in promoting the performance of design electrodes.

Research on Technology of Pulse Electrochemical and its Compound Finishing

In this paper, Pulse electrochemical finishing (PECF) and pulse electrochemical compound finishing (PECCF) are introduced. The main technical parameters, including in intereletrode gap, current density, compositions of steel materials and pulse parameters on the resulting surface finish were studied. PECF and PECCF on different surface including plane and shafts surface are done. Well-pleasing experimental results is gained. Results indicate that PECF and PECCF can lead to both good smoothing efficiency and surface finish simultaneity at low costs.

Research on Technology and Application of Pulse Electrochemical Finishing

Top-quality surfaces are obtained by means of pulse electrochemical finishing (PECF) in neutral electrolyte. The machining principles and advantages of PECF are analyzed. Moreover, the technique are applied to some typical cases such as sheeny lettering, fine and deep holes and complex shaped surface finishing, gear surface finishing that all of them are more difficult to be machined by the traditional finishing technologies. The results show mirror-like surfaces could be gained by PECF and the surface roughness values could be reduced from more than Ra 0.8 μm to less than Ra 0.08 μm within 1~2 seconds. It’s hoped that PECF will play an important role in finishing key parts in the modern manufacturing industries.

Research on pulse electrochemical finishing using a moving cathode

To improve the surface quality of parts with frictional pair, a finishing method – Pulse Electrochemical Finishing (PECF) using a Moving Cathode is studied in this paper. By experimentation we find: machining with an interelectrode gap as small as possible could smoothen the anode surface quickly; with an invariable gap size, the current density and the machining time are two key parameters influencing the smoothening effect; there is a critical current density above which a bright surface could be obtained, and this process could finish a large surface area over the critical current with a low power supply, which is helpful to get a lustrous surface. As an example, the inner surface of a part is finished. The result shows that the surface roughness value (Ra) reduces from 0.5 to 0.065 µm and a mirror-like surface is obtained.

On Characteristics of Flow-Field and Interelectrode Gap in Pulse Electrochemical Finishing (PECF)

On Characteristics of Flow-Field and Interelectrode Gap in Pulse Electrochemical Finishing (PECF)