| Electrochemical Milling achieves material removal based on electrochemical anode dissolution.It uses a simple shape of a rod-shaped tool cathode and uses a similar CNC machining method to control the high-speed rotation of the tool cathode to feed along a set processing path.A certain structure and surface can be machined on the workpiece.Electrochemical Milling has the advantages of no cutting force,no machining deformation and processing chatter,no tool wear,etc.Electrochemical Milling has the potential to process deformable thin plate parts such as aircraft skins.In this paper,simulation and experimental research are performed on Electrochemical Milling of silicon carbide particle reinforced aluminum matrix composites.The specific research contents are as follows:(1)Electrochemical characteristics of silicon carbide particles reinforced aluminum-based composites and their matrix materials are measured and compared,and the effect of reinforced silicon carbide particles on the electrochemical characteristics of materials is analyzed;(2)Using tool cathode with diameter of 15 mm,effects of process parameters,such as electrolyte pressure,initial processing gap,processing voltage,feed rate,on processing efficiency and processing depth are researched;(3)The defects of the tool cathode are analyzed,the structure of the tool cathode is improved,and a tapered recess is set at the bottom of the tool cathode to improve the flatness of the bottom surface of the processing groove.Through simulation analysis and experimental research,the flatness of the grooves machined by the cathode of the tool with different depths of the tapered pits was compared,and the optimal depth of the tapered pits was determined;(4)The influence of the amount of traverse on the flatness of the tool marks was studied,and the path of the tool was planned.A plane feature is machined with good results,using optimized process parameters,tool cathodes 11 and tool paths. |
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