Study On Optimization Of Machining Parameters In Ultrasonic Assisted Electrochemical Micro-Machining

Electrochemical machining (ECM), as a type of non-traditional machining process, is based on the principle of electrochemical anodic dissolution. In electrochemical machining, workpieces are formed according to specified shape and dimensions by means of the shaped cathode. Electrochemical machining has already become one of important machining methods in manufacturing industry.Electrochemical micro-machining (EMM) is referred to the electrochemical machining method by which micro-structures with size from a few microns to a few hundred microns can be machined with high precision. Theoretically EMM could machine the material ion by ion and has shown its potential in micro-electro-mechanical systems(MEMS).This thesis focus on the micro-holes with size of a few hundred microns in industry.In order to improve the machining accuracy of EMM, a new method of EMM with electrolyte disturbed by ultrasound is presented in the thesis. The author studied the influence of machining parameters on the EMM process. On the basis of EMM, various parameters affecting the machining accuracy and machining efficiency, such as pulse current, electrolyte concentration and ultrasound vibration are analysed in the thesis. By means of the ANASYS software distributions of electric field and flow velocity of electrolyte in inter-electrode gap are simulated.According to theories of artificial neural networks(ANN), a BP neural network model is used to describe the relationship between main machining parameters and machining effect. By the aid of the UG software the parameter optimization module is developed. Finally taking micro holes for machining examples, a serial of experiments have been carried on the digital EMM machine. And the BP model trained by using the experimental results is of good accuracy and practical worth.The optimization of machining parameters in ultrasonic assisted EMM is studied in the thesis. It presents prophase research and deeper theory, experiment and demonstration will be studied in future.