Profile Evolution And Experimental Study Of Magnetic-field Assisted Micro-electrochemical Machining Based On Finite Difference

With the development of the micron and nanometer era,the size and precision of difficult-to-cut metal parts and structures are getting smaller and higher.and the accuracy is getting higher and higher.With the advantages of no contact between tools and work-piece,smooth processing without burr,no wear of tools during processing,no stress on work-piece,etc.,the micro-ECM solves the problem of small size manufacturing,especially in the fields of aerospace,weapons and equipment,precision instruments and other fields.However,it is difficult to improve the machining accuracy of micro-ECM,so use introduce external magnetic field into micro-ECM to improve the machining accuracy,and further improve the machining accuracy by the method of profile prediction.However,there is a lack of research on the profile prediction of magnetic field composite micro-ECM.Therefore,this paper focuses on the simulation and experiment of profile evolution of magnetic field composite micro-ECM based on the finite difference theoretical model,and studies the simulation,experiment and parameter optimization of magnetic field composite micro-electrochemical machining profile based on the theoretical model.The main research contents are as follows:(1)In order to obtain finite-difference simulation model of magnetic field composite micro-ECM,the profile evolution model of magnetic field composite micro-ECM was first established by using Laplace,Butler-Volmer,surface erosion rate and other theoretical models,and then the profile evolution model based on finite difference was established by combining the ultra-relaxed iterative five-point finite difference scheme.(2)In order to solve the problem of predicting and simulating the profile of magnetic field compound micro-ECM,MATLAB software was used to simulate the finite-difference model of different parameter profiles of magnetic field assisted micro-ECM,such as machining voltage,machining gap,machining time,machining temperature and magnetic field intensity.By comparing the simulation results,an optimization parameter range was obtained: The machining voltage is 4V～4.5V,the machining temperature is 20℃～25℃,the machining gap is30μm,magnetic field intensity is 0.05T～0.15 T,and the machining time is 90 s.The comparison results show that the error of the simulation and experiment results is within 10%,which verifies the accuracy of the simulation.(3)In order to solve the problem that operators can obtain simulation results accurately and conveniently,a set of magnetic field composite micro-ECM profile evolution system was designed based on the MATLAB App designer software development platform.It mainly includes more than 10 modules,such as input module,output module,calculation module,login module,function selection module,simulation module,parameter selection module and return module,which can realize the accurate and convenient prediction function of the machining profile of the magnetic field composite micro-ECM under each parameter.The example shows that the system can obtain the simulation results of the magnetic field composite micro-ECM profile at this moment by the input of different parameters by the operator,and the example shows that the system reaches agreement with the simulation results.(4)In order to obtain the optimization parameters of magnetic field composite micro-ECM,improve the machining accuracy.The influence of machining voltage,machining gap,machining time,machining temperature and magnetic field intensity on the profile of magnetic field composite micro-ECM was obtained.Single-factor experiments with these parameters were designed.The experimental and simulation results were compared.The optimized parameters were obtained as machining voltage 4.5V,machining gap 30μm,machining time 90 s,machining temperature 20℃ and magnetic field intensity 0.1T.Based on the optimized parameters,a comprehensive experiment was carried out to verify the accuracy of the preliminary simulation and experimental optimization parameters.The profile simulation and experiment of magnetic field composite micro-ECM can effectively predict the shape of the machined work-piece.According to the designed profile evolution system of magnetic field composite micro-ECM,operators can accurately and conveniently obtain the simulation results under the corresponding input parameters.Finally,comprehensive experiments were carried out through the optimized parameters obtained by simulation and experiment.The experiments showed that the optimized parameters could improve the machining accuracy,and verified the accuracy of the optimized parameters obtained by the simulation and experiment of magnetic field composite micro-electrolysis profile evolution based on finite difference.