Advancing electrochemical jet methods through manipulation of the angle of address
Advancing electrochemical jet methods through manipulation of the angle of address
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DOI：
10.1016/j.jmatprotec.2017.12.026
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发表时间：
2018-05-01
影响因子：
6.3
通讯作者：
Clare, A. T.
中科院分区：
文献类型：
--
作者：
Mitchell-Smith, J.;Speidel, A.;Clare, A. T.
传统上，电化学喷射处理技术被认为仅限于与保持与工件表面垂直的电解液喷射的平面相互作用。在这项研究中，第一次研究了连接喷嘴相对于功的可行性和合成效果。定义了两个加工惯例：法线，其中射流保持垂直于横向方向；以及推/拉，其中喷嘴相对于移动方向旋转。人们发现，按照通常的惯例，可以创建一系列不同的合成轮廓曲面几何图形；这是该工艺所独有的。通过旋转头部发现的变化的侧墙坡度证明了这一点，切割墙的坡度之间的差异高达80%。喷流角接近90时，与喷管相邻的壁面斜率减小，而相对侧壁面斜率增大。然后，能够确定条纹侧壁的不同斜率的可预测比率。推拉惯例表明，由于喷嘴倾斜的高度局部化电流密度效应，在不需要额外能量的情况下，深度增加了35%，因此可以进行更深、更锐利的切割。此外，所得到的表面光洁度可以得到极大的改善，从而将轮廓粗糙度(R-α)从拉动模式下的0.2µm降低到推送模式下的0.04µm，从而实现镜面光洁度。对这些现象的机理进行了研究和定义。此外，还研究了喷嘴速度变化和喷嘴倾斜对喷嘴性能的影响。发现当喷嘴倾斜时，这对合成的轮廓没有明显的影响。相反，当喷嘴垂直于表面时，由于与加工碎屑清除不良和氧化物形成有关的极化效应，射流速度被认为具有直接影响。结果表明，通过改变喷射地址的角度，可以在电化学喷射过程中获得更高水平的灵活性和性能。
Electrochemical jet processing techniques have traditionally been considered to be limited to planar interactions with the electrolyte jet being maintained normal to the workpiece surface. In this study, the viability and resultant effects of articulating the nozzle relative to the work were investigated for the first time. Two machining conventions were defined, normal, where the jet is maintained perpendicular to the traverse direction, and push/pull, where the nozzle is rotated with respect to the direction of travel. It was found, with the normal convention that a range of differing resultant profile surface geometries could be created; unique to this process. This was demonstrated by the changing resultant side wall slopes found through the rotation of the head with up to 80% difference between the slopes of the cut walls. The adjacent wall to the nozzle slope decreasing as the jet angle approaches 90 whilst the opposite side wall slope increases. Predictable ratios of the differing slopes of the striation side walls were then able to be defined. The push/pull convention demonstrated that deeper, sharper cuts are possible due to the highly localising current density effect of nozzle inclination achieving a 35% increase in depth without requiring additional energy. Also, that resultant surface finish could be greatly improved, reducing the profile roughness (R-alpha) from 0.2 mu m in the pull mode to 0.04 mu m in the push mode achieving a mirror-like finish. The mechanics of these phenomena are investigated and defined. The influence of nozzle jet speed variation combined with inclining the jet was also studied. This was found to have no noticeable influence on the resultant profile when the nozzle is inclined. In contrast, when the nozzle is normal to the surface, jet velocity is seen to have a direct influence due to polarisation effects relating to the poor clearance of machining debris and the formation of oxides. It is shown that through variation of the angle of jet address an extra level of flexibility and performance is possible within electrochemical jet processes.