Burnishing and Electrofinishing in Screw Surface Polishing

2012 ◽  
Vol 430-432 ◽  
pp. 857-860
Author(s):  
P.S. Pa
Keyword(s):  
Direct Current ◽  
Low Cost ◽  
Surface Polishing ◽  
Finishing Process ◽  
Die Materials ◽  
Screw Surface ◽  
Burnishing Process ◽  
Partial Form ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing

The current study discusses the surface finish of several common die materials, of which the screw-surface is finished by compound processes of electrochemical finishing and burnishing. The burnishing-tool uses ceramic material connected with the electrode and moves, following the electrode, to burnish the workpiece. In the experiment, the electrode is used with a continuous and pulsed direct current. The results show that the use of a higher rotational speed for the electrode and burnishing-tool is advantageous to the finish. A partial form with a thinner heavy section performs the best finish effect in the current investigation. Pulsed direct current can slightly improve the finish effect. The burnishing process can increase the finish effect. An effective and low-cost finish processes through burnishing assistance following electrochemical finishing after screw machining offers a fast improvement for the surface roughness of the screw-surface and is a new application in the screw finishing process.

Design of Surface Finish Using Compound Processes of Grinding and Electrochemical Finishing Following Turning

2008 ◽  
Vol 373-374 ◽  
pp. 782-785 ◽  
Author(s):  
Pai Shan Pa
Keyword(s):  
Direct Current ◽  
Feed Rate ◽  
Rotational Speed ◽  
Low Cost ◽  
Electrical Current ◽  
High Rotational Speed ◽  
Factors Affecting ◽  
Grinding Tool ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing

A new finish method uses an effective electrode connecting with a nonconductive grinding tool to execute the design of compound processes of electrochemical finishing and grinding following turning is investigated. The submitted processes can be used for various turning operations. Through simple equipment attachment, electrochemical finishing and grinding can follow to execute the finishing process on the same machine. Among the factors affecting electrochemical finishing the performance of grinding combined with electrochemical finishing is primarily discussed. In the experiment, the electrode is used with continuous and pulsed direct current. The grinding tool moves following the electrode and grinds the workpiece surface. The experimental parameters are electrical current rating, feed rate of electrode and grinding tool, rotational speed of workpiecel, pulsed period, and geometry of finish-tool. The results show that pulsed direct current with longer off-time can slightly improve the finish effect for its dregs discharge mobility. Using an adequate rotational speed of workpiece with high rotational speed is advantageous to the finish effect. A thinner plate-form electrode with a smaller end radius is associated with larger discharge space and produces higher current density and provides faster feed rate and a better finish effect. The grinding can effectively increase the finish effect. An effective and a low-cost finish process through the design electrode and using the grinding assistance in the electrochemical finishing after turning process make the surface of workpiece 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.

Rolling-Leveling Assistance in Ultrasonic Electrochemical Finishing of External Cylindrical Surface

2008 ◽  
Vol 44-46 ◽  
pp. 455-462 ◽  
Author(s):  
Pai Shan Pa
Keyword(s):  
Direct Current ◽  
Rotational Speed ◽  
Design Tool ◽  
Surface Finishing ◽  
Tool Geometry ◽  
Tool Electrode ◽  
Finishing Process ◽  
Pulsed Direct Current ◽  
Electrochemical Finishing ◽  
Better Than

A new tool product consists of an effective electrode and a nonconductive roller utilizing rolling-leveling assistance in ultrasonic electrochemical finishing, as a continuous surface finishing process following turning is investigated. Through a simple equipment attachment, ultrasonic electrochemical finishing and rolling-leveling can follow to execute the finishing process on the same machine. The submitted processes may be used for various turning operations. Among the factors affecting rolling-leveling combined with the ultrasonic electrochemical finishing, the performance of the design tool product is primarily discussed. In the experiment, the electrode is used with a continuous and a pulsed direct current. The experimental parameters are frequency and power level of ultrasonics, die material, electrical current rating, feed rate of tool electrode and roller, rotational speed of the workpiece, pulsed period, and tool geometry. A higher workpiece rotational speed produces a better finishing result. The design change of the tool from a semicircle to a wedge-form with small end radius brings about a reduction of the electrolytic dregs and heat more rapidly, and performs the best finishing result. The finishing effect of pulsed direct current is slightly better than using continuous direct current. The average effect of the ultrasonics is better than the pulsed current, while the machining time does not need to be prolonged by the off-time. An effective and low-cost finish process through the tool product design utilizing the rolling-leveling assistance in the ultrasonic electrochemical finishing after the turning process make the surface of the workpiece smooth and bright in a shorter period of time.

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.

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.

Design of Sword-Form Electrode and Ultrasonic-Aid in Electrochemical Finishing of AISI 4340 Surface

2007 ◽  
Vol 364-366 ◽  
pp. 674-679
Author(s):  
Pai Shan Pa
Keyword(s):  
Low Cost ◽  
Power Level ◽  
Wedge Angle ◽  
Surface Finishing ◽  
Polishing Process ◽  
Nickel Chromium ◽  
Finishing Process ◽  
Experimental Parameters ◽  
Die Material ◽  
Electrochemical Finishing

It is difficult to execute the polishing process for swords surface. This study provides a design of sword-form electrode and a new area finishing process using an ultrasonic energy transmitted into the electrolyte to assist the process of electrochemical finishing on the surface of nickel chromium steels beyond traditional polishing process of sword surface instead of the conventional hand or machines surface finishing. The surface of the sword is electrochemically finished by different types of feeding electrodes as a finishing operation. In the experiment, four types of electrode were used with continuous direct current and axial electrode feed applied. The controlled factors included the chemical composition and concentration of the electrolyte, die material, initial gap width, and flow rate of electrolyte. The experimental parameters were current rating, feed rate of electrode, frequency and power level of ultrasonics, and electrode geometry. The higher current rating with ultrasonic assistance can avoid the difficulty of dregs discharge, thus reducing the finishing time. For the design of electrodes, an electrode of arc-end shape with small end radius and small wedge angle provides larger discharge space and better finishing effect. The electrode of round-pin shape with semicircular end is associated with higher current density and provides more opening discharge space and performs best. A low-cost and effective finishing process of the sword surface is presented. It is a great contribution that the ultrasonic-aided electrochemical finishing after sword finish just needs quite a shorter time than manual or machine polishing to make the surface of swords smooth and bright.

Development of the Pulsed Direct Current Iontophoresis and Its Clinical Application

PIERS Online ◽  
2006 ◽  
Vol 2 (2) ◽  
pp. 157-162
Author(s):  
Makio Akimoto ◽  
Makoto Kawahara ◽  
Mayumi Matsumoto ◽  
Hidekazu Matsubayashi
Keyword(s):  
Clinical Application ◽  
Direct Current ◽  
Pulsed Direct Current

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

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.

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