Effect of Cavitation Micro-jet in Interelectrode Gap on Material Erosion in Ultrasonic Assisted Electrochemical Micromachining

doi:10.12382/bgxb.2022.0318

Abstract

Abstract:

A fluid-structure coupling model of themicro-jet impactingthe workpiece surface is established to investigate the effect of cavitation micro-jet generated in the interelectrode gap in ultrasonic assisted electrochemical micromachining (UAEMM) on material erosion. The micro-plastic deformation of theworkpiece surface impacted by the high-speed micro-jet and the influence of micro-deformation on electric field distribution are studied through numerical simulations, and verified by ultrasonic cavitation experiments. The results show that several corrosion pits with adepth of about 0.12μm and a bulge of about 0.04μm are generated on the workpiece surface after the micro-jetimpact. Under the influence of an external electric field, the current density and erosion depth of the bulge of the corrosion pit are 1.2 times higher than that of the original workpiece surface. Furthermore,compared with electrochemical micromachining (EMM), the experimental results of pit forming processing in UAEMM reveal that the removal depth of the pit is increased from 20μm to 100μm and that the surface roughness of the pit bottom is reduced from R_a 290nm to R_a 40nm at the conditions of 10μm ultrasonic amplitude, 5s processing time and 50μm interelectrode gap. A large number of cavitation micro-jets inthe gap under ultrasonic energy can improve the machining efficiency and surface quality in EMM.

Key words: ultrasonic assistance, electrochemical micromachining, cavitation micro-jet, corrosion pit, material erosion

CLC Number:

TG662

WANG Minghuan, LÜ Ming, HE Kailei, ZHENG Jinsong, XU Xuefeng. Effect of Cavitation Micro-jet in Interelectrode Gap on Material Erosion in Ultrasonic Assisted Electrochemical Micromachining[J]. Acta Armamentarii, 2023, 44(8): 2368-2380.

Figures/Tables 26

Fig.1 Schematic diagram of UAEMM

Table 1 Parameters of cavitation micro-jet

加工参数	数值
电解液中声速/(m·s^-1)	1450
电解液的密度/(kg·m^-3)	1067
泡内蒸气压强/Pa	2330
声压幅值/MPa	0.9
电解液压强/MPa	0.1

Table 2 Material characteristic parameters

材料	伸长率/%	泊松比	杨氏模量/MPa	黏度/ (MPa·s)	声速/ (m·s^-1)	密度/ (kg·m^-3)
6061 铝合金	20	0.33	74500		6320	2750
电解液				1×10^-9	1450	1067

Table 3 Johnson-Cookconstitutive parameters of Al 6061[27]

σ_s/MPa	γ/MPa	n	S	m	T₀/K	T_m/K
104.08	83.53	0.36	0.041	2.387	293	925

Fig.2 Geometric model of micro-jet

Fig.3 Mesh generation

Fig.4 Impact of micro-jet at different moments

Fig.5 Equivalent stress distributions of workpiece surface at different moments

Fig.6 Deformation of workpiece surface at different moments

Fig.7 Cross-section curves of pits at different moments

Fig.8 Deformation of workpiece surface at different micro-jet diameters

Fig.9 Cross-section curves of pits at differentmicro-jet diameters

Fig.10 Experimental setup for UAEMM

Table 4 Experimental parameters for UAEMM

工艺参数	数值
电解液配比(NaNO₃∶H₂O)	1∶9
加工电压/V	10
加工间隙/μm	40,50,60,70
超声频率/kHz	28
超声振幅/μm	1,4,7,10
加工时间/s	5

Fig.11 Morphology of workpiece surface before and after 0.1s ultrasonic treatment

Fig.12 Profile comparison between simulated and experimental results

Fig.13 Geometric model

Fig.14 Current densityofworkpiece surface

Fig.15 Erosion depthof workpiece surface

Fig.16 Pit of UAEMMand its bottom morphology

Fig.17 Pit of EMM and its bottom morphology

Fig.18 Pit profile curves of EMM and UAEMM

Fig.19 Pit profile curves under different ultrasonic amplitudes

Fig.20 Effect of ultrasonic amplitude on pit removal amount and surface roughness

Fig.21 Pit profile curves under different interelectrode gaps

Fig.22 Effect of interelectrode gap on pit removal amount and surface roughness

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