A new mechanism design 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 end-turning is investigated in the current study. Through simple equipment attachment, magnetic-assistance during electrochemical finishing can follow the cutting process on the same machine. This process can be used for various end-turning operations. Among the factors affecting electrochemical finishing, the magnetic-assistance is primarily discussed. The experimental parameters are chemical composition and concentration of the electrolyte, flow rate of the electrolyte, initial gap width, current rating, on/off period of pulsed current, feed rate of workpiece, rotational speed of workpiece and electrode, magnetic strength, and distance between the two magnets. 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.
This study discusses the electrochemical smoothing and electrobrightening of medium or large holes beyond traditional drilling, boring, turning, or extruding using both inserted and feeding electrodes of borer-rib type for several common die materials. High electrical current is not required when the electrode of borerrib type is employed to reduce the engaged area for large holes. Traditionally, the hole polishing of a die requires a sequence of complicated premachining or some manual skill. In the current experiment, six types of electrode are completely inserted and connected to both continuous and pulsed direct current, while another six types of electrode are fed into holes using continuous direct current. The design features of the electrodes are of major interest for effective electrochemical smoothing of holes. The controlled factors include the diameter of the electrode as well as the chemical composition and concentration of the electrolyte. The experimental parameters are current density, current rating, electrode design, die material, rotational speed, and feed rate of electrode. For the inserted electrodes, the single-plate electrode performs better than the double-plate electrode, and the single-plate electrode with half borer gives the best polishing effect. Pulsed direct current can slightly improve the polishing effect but at the expense of increased machining time and cost. For the feeding electrodes, the electrode of one-side borer tip with half borer performs the best polishing. It was also found that the electrobrightening after precise boring takes only a short time to make the hole bright, while the electrochemical smoothing saves the need for reaming, making the total processing time less than that required for electrobrightening.
This study presents a new nanotechnology application involving an ITO thin-film removal reuse process using an eccentric-form negative electrode, offering a fast removal rate from the surface of liquid crystal displays (LCDs). For the precision removal process, a small amount of eccentricity of the negative electrode or a higher rotational speed of the negative electrode corresponds to a higher etching rate for the ITO. A higher flow velocity of the electrolyte and a higher working temperature also correspond to a higher removal rate. The average effect of the eccentricity is better than the effects of a pulsed current, while the current rating need not be prolonged by the off-time.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.