Rolling-Leveling Assistance in Ultrasonic Electrochemical Finishing ofExternal Cylindrical Surface

摘要

A new tool product consists of an effective electrode and a nonconductive roller utilizingrolling-leveling assistance in ultrasonic electrochemical finishing,as a continuous surface finishingprocess following turning is investigated.Through a simple equipment attachment,ultrasonicelectrochemical finishing and rolling-leveling can follow to execute the finishing process on the samemachine.The submitted processes may be used for various turning operations.Among the factorsaffecting rolling-leveling combined with the ultrasonic electrochemical finishing,the performance ofthe design tool product is primarily discussed.In the experiment,the electrode is used with acontinuous and a pulsed direct current.The experimental parameters are frequency and power level ofultrasonics,die material,electrical current rating,feed rate of tool electrode and roller,rotationalspeed of the workpiece,pulsed period,and tool geometry.A higher workpiece rotational speedproduces a better finishing result.The design change of the tool from a semicircle to a wedge-formwith small end radius brings about a reduction of the electrolytic dregs and heat more rapidly,andperforms the best finishing result.The finishing effect of pulsed direct current is slightly better thanusing 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-costfinish process through the tool product design utilizing the rolling-leveling assistance in the ultrasonicelectrochemical finishing after the turning process make the surface of the workpiece smooth andbright in a shorter period of time.