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 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.

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.

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.

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.

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.

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 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.

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.

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.

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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