Design of freeform surface finish using burnishing assistance following electrochemical finishing

2007 ◽  
Vol 21 (10) ◽  
pp. 1630-1636 ◽  
Author(s):  
P. S. Pa
Keyword(s):  
Surface Finish ◽  
Freeform Surface ◽  
Electrochemical Finishing

5-Axis Freeform Surface Milling Using Piecewise Ruled Surface Approximation

1997 ◽  
Vol 119 (3) ◽  
pp. 383-387 ◽  
Author(s):  
G. Elber ◽  
R. Fish
Keyword(s):  
Surface Finish ◽  
End Milling ◽  
Ruled Surface ◽  
Freeform Surface ◽  
Freeform Surfaces ◽  
Surface Approximation ◽  
Side Milling ◽  
Scallop Height ◽  
Ball End Milling ◽  
Milling Operation

This paper presents a 5-axis side milling scheme for freeform surfaces based on automatic piecewise ruled surface approximation. With this scheme, resulting surface finish is accurate and pleasing, and has a smaller scallop height compared to ball-end milling. The ruled surface approximation can be made arbitrarily precise resulting in an overall fast milling operation that satisfies tight tolerances, and smoother surface finish. The class of surfaces that can take advantage of this type of 5-axis milling operation includes both convex and saddle-like (hyperbolic) shapes.

Design of Surface Finish Using Synchronous Process of Grinding and Electrochemical Finishing

2007 ◽  
Vol 359-360 ◽  
pp. 259-263
Author(s):  
Pai Shan Pa
Keyword(s):  
Surface Roughness ◽  
Flow Rate ◽  
Surface Finish ◽  
Feed Rate ◽  
Rotational Speed ◽  
Machining Process ◽  
Grinding Wheel ◽  
High Rotational Speed ◽  
Plate Electrode ◽  
Electrochemical Finishing

In order to elevate the efficiency of the surface finish to reach the fast improvement of the surface roughness of the workpiece, so as to reduce the residual stress on the surface efficiently. The present study discusses the surface after traditional machining, of which the plane surface used a design of finish tool includes an electrode and a nonconductive grinding wheel to execute the synchronous process of grinding and electrochemical finishing. The electrode form and the machining process are obviously different from electrochemical grinding (ECG). In the experiment, the design electrode is used with continuous and pulsed direct current. The controlled factors include die material, and chemical composition and concentration of the electrolyte. The experimental parameters are flow rate of electrolytes, position of plate electrode, electrode thickness, electrode rotational speed, electrical current rating, feed rate of workpiece, and pulsed period. The experimental results show that the supply of current rating is near concern with the position and thickness of the plate electrode. The use of large electrolytic flow rate and thick electrode is advantageous to the finish effect. High rotational speed of finish tool produces better polishing. The finishing effect is better with longer off-time because discharge of polishing dregs becomes easier. Higher current rating with quicker workpiece feed rate effectively reaches the fast improvement of the surface roughness of the workpiece is recommend in current study.

Design of Product Surface Finish via Magnetic-Assistance

2010 ◽  
Vol 126-128 ◽  
pp. 463-468
Author(s):  
Pai Shan Pa
Keyword(s):  
Magnetic Force ◽  
Freeform Surface ◽  
Design System ◽  
Zinc Alloy ◽  
Machining Time ◽  
Finish Process ◽  
Product Surface ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing ◽  
Effective Design

This paper studies the performance assessment of magnetic-assistance electrochemical finishing using an effective design system and magnetic force to the electrolyte to assist the dregs discharge on zinc alloy beyond die casting by electrochemical finishing as a finish process on the freeform surface of castings. An outer shell of toy vehicle is taken for instance in the experiment. A small distance between the two magnets or large magnetic field intensity provides larger magnetic force and discharge ability. A higher current rating with magnetic-assistance can avoid the difficulty of dreg discharge, thus reducing the finish time. Pulsed direct current can slightly promote the finishing effect, but the machining time is increased. Thus the magnetic-assistance electrochemical finishing without pulsed current is recommended for the finish process. It is a great contribution that the magnetic-assistance electrochemical finishing just needs quite short to make the freeform surface of workpiece smooth and bright.

Performance Assessment of Design Electrode in Ultrasonic-Aided of Freeform Surface Finishing

2007 ◽  
Vol 364-366 ◽  
pp. 680-685
Author(s):  
Pai Shan Pa
Keyword(s):  
Low Cost ◽  
Power Level ◽  
Wedge Angle ◽  
Electrical Current ◽  
Freeform Surface ◽  
Small Radius ◽  
Surface Finishing ◽  
Finishing Process ◽  
Electrochemical Finishing ◽  
Effective Design

The most effective geometry for design electrode and the advantage of low cost equipment in ultrasonic-aided electrochemical finishing for a freeform surface following turning machining was investigated. The proposed design process used an effective electrode instead of the mate electrode as in conventional ECM. Hence higher electrical current is not required when the effective design electrode is used to reduce the response area. Through simple equipment attachment, electrochemical finishing can follow the traditional cutting on the same machine. The controlled factors included the chemical composition and concentration of the electrolyte, the initial gap width, the flow rate of electrolyte, workpiece rotational speed, and die material. The design electrode is primarily discussed among the factors affecting the electrochemical finishing. The experimental parameters were current rating, electrode feed rate, frequency , power level of ultrasonics, and electrode geometry. The effective design electrode with small wedge angle and small edge rounding radius had an optimal value for higher current density and provided larger discharge space, which produce a smoother surface. The electrode of globe-shape with small radius performed best in the finishing process. The electrochemical finishing needed only a short time to make the workpiece smooth and bright and save the need for the precise process of traditional machining. The ultrasonic-aided electrochemical finishing is recommended for the finishing process of the freeform surface.

Design of Freeform Surface Finish Using Synchronous Processes of Electrochemical Finishing and Burnishing

2008 ◽  
Vol 375-376 ◽  
pp. 308-312 ◽  
Author(s):  
Pai Shan Pa
Keyword(s):  
Flow Rate ◽  
Feed Rate ◽  
Rotational Speed ◽  
Low Cost ◽  
Electrical Current ◽  
Freeform Surface ◽  
Design System ◽  
High Rotational Speed ◽  
Electrochemical Finishing ◽  
Effective Design

A most effective design system and an advantage of low cost equipment using synchronous processes of electrochemical finishing and burnishing for a freeform surface following turning machining is investigated. The proposed design process uses a feeding finish-tool instead of the mate electrode as in conventional ECM. Hence higher electrical current is not required when the effective design electrode is used to reduce the response area. Through simple equipment attachment, electrochemical finishing can follow the traditional turning on the same machine. The controlled factors include the chemical composition and concentration of the electrolyte, die material, and rotational speed of workpiece. The design finish-tool is primarily discussed among the factors affecting the synchronous processes of electrochemical finishing and burnishing. The experimental parameters are initial gap width, flow rate of electrolyte, current rating, feed rate of finish tool, pulsed period, and the evaluation of different process features. The use of large electrolytic flow rate is advantageous to the finish effect. High rotational speed of the finish tool produces better finish. The finish effect is better with longer off-time because discharge of finish dregs becomes easier. Higher current rating with quicker feed rate of finish tool effectively reaches the fast improvement of the surface roughness of the workpiece is recommend in current study. The effective design finish-tool with an electrode of a globe-form and a burnishing tool of a pin-form have an optimal value for higher current density and provides larger discharge space, which produces a smoother surface. The synchronous processes of electrochemical finishing and burnishing just needs only a short time to make the workpiece smooth and bright and saves the need for the precise process of traditional machining is recommended for the finish process of the freeform surface.

scholarly journals Corrective Abrasive Polishing Processes for Freeform Surface

2009 ◽  
Vol 404 ◽  
pp. 103-112 ◽  
Author(s):  
Xun Chen
Keyword(s):  
Surface Finish ◽  
Freeform Surface ◽  
Current Development ◽  
Regular Form ◽  
Freeform Surfaces ◽  
Finishing Process ◽  
Abrasive Finishing

Traditionally, abrasive finishing process only focused on producing excellent surface finish on regular form shapes. Ever increasing demands in freeform features in aerospace, energy and medicine applications require abrasive finishing technology not only provides excellent surface finish but also is capable to correct the errors on freeform surfaces. The paper presents current development of corrective polishing technology for freeform surfaces.

Research on Technology of Pulse Electrochemical and its Compound Finishing

2009 ◽  
Vol 416 ◽  
pp. 82-86
Author(s):  
Hong You Li ◽  
Yin Biao Guo ◽  
Xiao Mei Liu ◽  
Jin Jin Zhou
Keyword(s):  
Current Density ◽  
Surface Finish ◽  
Experimental Results ◽  
Technical Parameters ◽  
Pulse Parameters ◽  
Low Costs ◽  
Electrochemical Finishing

In this paper, Pulse electrochemical finishing (PECF) and pulse electrochemical compound finishing (PECCF) are introduced. The main technical parameters, including in intereletrode gap, current density, compositions of steel materials and pulse parameters on the resulting surface finish were studied. PECF and PECCF on different surface including plane and shafts surface are done. Well-pleasing experimental results is gained. Results indicate that PECF and PECCF can lead to both good smoothing efficiency and surface finish simultaneity at low costs.

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