Effects Of Electrical Parameters On Milling Parameters Of Magnetic-field-assisted Micro-ECM

With the rapid development of micro-nano technology,nickel-based alloys,titanium alloys and other difficult-to-cut metal microstructures have been widely applied in aerospace,aerospace,military,and precision instruments.Traditional mechanical cutting technologies and some non-traditional technologies are difficult to machine.Micro electrochemical machining(micro-ECM)technology is a metal machining technology based on the principle of electrochemical anode dissolution and removes extra material in the form of ions.It has unique advantages and broad application prospects in the area of machining microstructures of difficult-to-cut metal materials.But the machining localization and precision of this technology are not high,in this thesis,external magnetic field is introduced into the micro-electrochemical machining technology.In order to improve the localization and precision of micro-ECM,the Lorentz force is used to effect the motion of charged ions in the solution.The effects of electrical parameters on the milling parameters was studied.The main research works are as follows:(1)The magnetic field is applied into the micro-ECM,the theory is analyzed from three aspects of current density,hydrogen bubble motion trajectory,and mass transfer.Simulation software is used to simulate the current density and mass transfer.The results show that the current density is increased by the external magnetic field,and the mass transfer is enhanced by the external magnetic field.(2)To know the effects of electrical parameters on the milling parameters,research works have been done from theoretical and experimental aspects.The electrode process and the double electrical layer structure were analyzed with Faraday's,calculus and electronic circuits principles.The gap of machining model was established.The mathematical model of the effects of the electrical parameters on the milling parameters was obtained and it was verified by a large numbers of experiments.(3)In order to apply the effects of electrical parameters on the milling parameters into the actual machining process,a set of software systems was developed to solve the problem of parameters matching with using tools such as Visual Basic programming language and MySQL database.(4)The material 3J21 was selected as the anode,the parameter matching software system was used to match machining parameters and a machining experiment was carried out with the technology of magnetic-field-assisted micro-ECM.A micro-groove structure with width of 101?m and depth of 15.5?m was machined.The corners of 30?60?90 were clearly in the structure.The results show the localization can be improved by magnetic,and the validity of the software system be verified by the experiment.It is helpful for promoting the application of micro-ECM milling technology in formation and machining of micro-strutcture on difficult-to-cut material.Meanwhile,it has a significance for the improvement of composite micro-ECM technology.