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.

A Magnetic-Assistance System as a Super Finishing Following Turning Machining

2013 ◽  
Vol 683 ◽  
pp. 937-940
Author(s):  
P.S. Pa
Keyword(s):  
Rotational Speed ◽  
Magnetic Force ◽  
High Efficiency ◽  
Machining Process ◽  
Design System ◽  
Electrode Gap ◽  
Factors Affecting ◽  
Magnetic Strength ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing

A design system using a magnetic force with high efficiency to assist discharging dregs out of the electrode gap during the electrochemical finishing on the surface finish process that follows turning machining process is investigated in the current study. Through the equipment attachment, magnetic-assistance during electrochemical finishing can follow the turning process on the same machine. This process can be used for various turning operations. Among the factors affecting electrochemical finishing, the magnetic-assistance is primarily discussed. The experimental parameters are magnetic strength, distance between the two magnets, current rating, on/off period of pulsed current, feed rate of workpiece, and rotational speed of workpiece. A higher current rating with magnetic-assistance reduces the finishing time and avoids the difficulty of dreg discharge. Providing a large magnetic field intensity or using a small distance between the two magnets produces a larger magnetic force and discharge ability and better finishing. A large rotational speed of the workpiece and electrode produces better finishing. Pulsed direct current can slightly promote the effect of electrochemical finishing, but the current rating needs to be increased. The magnetic-assistance during the electrochemical finishing process makes a great contribution in a short time by making the surface of the workpiece smooth and bright.

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.

Compound Finish Processes Using Burnishing and Ultrasonic Electrochemical Finishing on Hole-Wall Surface

2008 ◽  
Vol 53-54 ◽  
pp. 3-8
Author(s):  
Pai Shan Pa
Keyword(s):  
Wall Surface ◽  
Machining Time ◽  
High Rotational Speed ◽  
Hole Wall ◽  
Finishing Processes ◽  
Pulsed Direct Current ◽  
Short Time ◽  
Electrochemical Finishing ◽  
Off Time ◽  
Better Than

This study using ultrasonic energy transmitted into the electrolyte to assist in discharging of electrolytic product out of the machining gap in the compound finishing processes of electrochemical finishing and burnishing on hole-wall surface beyond traditional process of holes machining instead of conventional hand or machine polishing. The design finish-tool includes a burnishing-tool and an electrode as a hole-wall surface finish improvement that goes beyond traditional rough boring. In the experiment, the finish-tool travels across the hole-wall surface with continuous or pulsed direct current. The experimental results show that the large supply of current rating is effectively to reach the amount of the material removal and is advantageous to the finishing processes. The average effect of the ultrasonic is more better than the pulsed current while the machining time needs not to be prolonged by the off-time. The finish effect is better with a high rotational speed of the finish-tool because the dregs discharge of electrochemical finishing becomes easier and is also advantageous to the finish. The compound processes of burnishing and ultrasonic electrochemical finishing just require a short time to make the hole-wall surface smooth and bright.

Compound Finish Processes Using Grinding and Ultrasonic Electropolishing on Hole-Wall Surface

2012 ◽  
Vol 426 ◽  
pp. 205-208
Author(s):  
P.S. Pa
Keyword(s):  
Wall Surface ◽  
Machining Time ◽  
High Rotational Speed ◽  
Hole Wall ◽  
Grinding Tool ◽  
Finishing Processes ◽  
Pulsed Direct Current ◽  
Short Time ◽  
Electrochemical Finishing ◽  
Polishing Tool

This study using ultrasonic energy transmitted into the electrolyte to assist in discharging of electrolytic product out of the machining gap in the compound finishing processes of grinding and electropolishing on hole-wall surface beyond traditional process of holes machining instead of conventional hand or machine polishing. The compound processes of grinding and ultrasonic electro polishing just require a short time to make the hole-wall surface smooth and bright in the current study. The design polishing tool includes a grinding-tool and an electrode as a hole-wall surface finish improvement that goes beyond traditional rough boring. In the experiment, the polishing tool travels across the hole-wall surface with continuous or pulsed direct current. The experimental results show that the large supply of current rating is effectively to reach the amount of the material removal and is advantageous to the finishing processes. The average effect of the ultrasonic is better than the pulsed current while the machining time needs not to be prolonged by the off-time. The finish effect is better with a high rotational speed of the polishing tool because the dregs discharge of electrochemical finishing becomes easier and is also advantageous to the finish.

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.

Synchronous Finish Processes Using Grinding and Ultrasonic Electrochemical Finishing on Hole-Wall Surface

2008 ◽  
Vol 389-390 ◽  
pp. 295-301
Author(s):  
Pai Shan Pa
Keyword(s):  
Machining Process ◽  
Wall Surface ◽  
Machining Time ◽  
High Rotational Speed ◽  
Hole Wall ◽  
Grinding Tool ◽  
Pulsed Direct Current ◽  
Short Time ◽  
Electrochemical Finishing ◽  
Electrochemical Grinding

The current study using ultrasonic energy transmitted into the electrolyte to assist in discharging of electrolytic product and cuttings out of the machining gap in the synchronous finish processes of grinding and electrochemical finishing on hole-wall surface beyond traditional process of holes machining instead of conventional hand or machine polishing. The design finish-tool includes a grinding-tool and an electrode as a hole-wall surface finish improvement that goes beyond traditional rough boring. In the experiment, the finish-tool is completely inserted to the hole; the electrode is used with continuous or pulsed direct current. The electrode form and the machining process are obviously different from electrochemical grinding (ECG). The experimental results show that the large supply of current density is effectively to reach the amount of the material removal and is advantageous to the finish processes. The finish effect is better with a high rotational speed of the finish-tool because the dregs and cuttings discharge of electrochemical finishing and grinding becomes easier and is also advantageous to the finish. The average effect of the ultrasonics is more better than the pulsed current while the machining time needs not to be prolonged by the off-time. The synchronous processes of grinding and ultrasonic electrochemical finishing just require a short time to make the hole-wall surface smooth and bright.

Design of Synchronous Processes of Rolling-Leveling and Ultrasonic Electrochemical Finishing of Holes

2009 ◽  
Vol 83-86 ◽  
pp. 785-792
Author(s):  
Pai Shan Pa
Keyword(s):  
Rotational Speed ◽  
Low Cost ◽  
Power Level ◽  
Electrical Current ◽  
Machining Time ◽  
Factors Affecting ◽  
Finishing Process ◽  
Finishing Processes ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing

A new finishing method of holes that uses an effective electrode and a nonconductive roller to execute the design of synchronous processes of ultrasonic electrochemical finishing and rolling-leveling is investigated. The submitted processes can be used among the traditional techniques of various holes machining. Through simple equipment attachment, ultrasonic electrochemical finishing and rolling-leveling can follow to execute the finishing process on the same machine. Among the factors affecting finishing processes, the performance of rolling-leveling combined with ultrasonic electrochemical finishing is primarily discussed. In the experiment, the electrode is used with continuous and pulsed direct current. The controlled factors include roller material, roller geometry, chemical composition and concentration of the electrolyte, and flow rate of electrolytes. The experimental parameters are frequency and power level of ultrasonics, feed rate of electrode and roller, rotational speed of the finish-tool, die material, electrical current rating, and pulsed period. The design of the synchronous processes through rolling-leveling is the most influential parameter in this study. An adequate finish-tool rotational speed produces better finishing. The average effect of the ultrasonic is better than the pulsed current while the machining time needs not to be prolonged by the off-time. An effective and low-cost finishing process through the ultrasonic electrochemical finishing and using the rolling-leveling assistance after the process of traditional holes machining make the surface of the holes smooth and bright is presented.

Performance Assessment of Surface Finishing Using Completely Inserted Module of Female-Screws

2009 ◽  
Vol 628-629 ◽  
pp. 647-650
Author(s):  
Pai Shan Pa
Keyword(s):  
Direct Current ◽  
Convex Surface ◽  
Surface Finishing ◽  
Machining Time ◽  
Finishing Process ◽  
Form Design ◽  
The Cost ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing ◽  
Better Than

It is very difficult to execute the finishing process of the concavo-convex surface of female-screws. The current study offers a screw-form design electrode and a new area-finishing process using an ultrasonic generator. The ultrasonic energy generated is transmitted into the electrolyte to assist the process of electrochemical finishing. The surface of female-screws is electrochemically finished by different types of completely inserted electrodes and put through both continuous and pulsed direct current as a finishing operation. For inserted screw-form electrodes, a smaller circumference electrode on the cylinder provides more sufficient discharge space, which is advantageous for finishing. Pulsed direct current can promote the effect of electrochemical finishing, but the machining time is longer and the cost is raised. The average ultrasonic effect is much better than the pulsed current while the machining time needs not be prolonged by the off-time. The higher current density and higher current rating with ultrasonic assistance can avoid the difficulty of dreg discharge, thus reducing the finishing time. It is a great contribution that the ultrasonic-assistance electrochemical finishing after screw machining requires a shorter time than manual or machine polishing to make the surface of female screws smooth and bright.

Automation Finish Processes of Sword Surface Using Burnishing Assistance

2008 ◽  
Vol 594 ◽  
pp. 214-219
Author(s):  
Pai Shan Pa
Keyword(s):  
Flow Rate ◽  
Feed Rate ◽  
High Efficiency ◽  
Low Cost ◽  
Electrical Current ◽  
Design Tool ◽  
Machining Time ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing ◽  
Finishing Tool

A new method of automated finishing that employs a nonconductive stone as the burnishing tool to execute burnishing assistance in electrochemical finishing following sword machining is investigated. The submitted processes can be used for various sword-form operations. Among the factors primarily discussed is the performance of electrochemical finishing combined with burnishing. In the experiment, an electrode is used with continuous and pulsed direct current. The controlled factors include the material of burnishing tool, the geometry of burnishing tool, and the chemical composition and concentration of the electrolyte. The experimental parameters are flow rate of electrolytes, feed rate of electrode and burnishing tool, electrical current rating, and pulsed period. Higher current rating with a quicker feed rate of the finishing tool effectively reaches the fast improvement of the surface roughness of the workpiece. The use of a large electrolytic flow rate is advantageous to the finish effect. The finish effect is better with longer off-time because discharge of the finish dregs becomes easier. The use of pulsed current, however, raises the machining time and cost. The design change of the electrochemical finishing to the electrochemical finishing and burnishing performs the best finishing make the surface of the swords smooth and bright. An effective and low-cost automation and the continuity finish processes through the design tool and using the burnishing assistance in the electrochemical finishing are high efficiency and low-cost means.

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