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Study on improving the surface roughness of multi-stage internal cone hole by rotating magnetic field assisted electrochemical machining

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Abstract

In order to further improve the surface quality of electrochemical machining multi-stage internal cone hole parts, the method of rotating magnetic field–assisted electrochemical machining is proposed in this paper, a new cathode structure which inlaid Nd-Fe-B permanent magnet on the side wall was designed, and the simulation study on the effect of the magnetic field on the uniformity of the flow field in the machining gap was carried out. Under the conditions of 7 V, 5 mm/min cathode feed speed, 0.15 r/s cathode rotation speed, composition electrolyte 5%NaCl+15%NaNO3+5%NaClO3, electrolyte temperature 30°C, and inlet pressure 1.6 MPa, a comparative experiment of electrochemical machining with and without a rotating magnetic field was conducted. The results show that under the same machining parameters, when there is no magnetic field, the surface roughness of the workpiece is Ra0.847μm, while when a rotating magnetic field is added, the surface roughness of the workpiece is Ra0.437μm. The workpiece surface quality of the multi-stage internal cone hole is improved by 48.41%. It indicates that the rotating magnetic field can change the flow direction of the electrolyte and improve the uniformity of the flow field in the machining gap. Adding a rotating magnetic field is an effective method to improving the surface quality of electrochemical machining.

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Funding

This work was financially supported by Shaanxi Province Key Research and Development projects (Grant No. 2020GY-153), Shaanxi Provincial Education Department service local special plan project (Grant No. 17JF010), the National Natural Science Foundation of Shaanxi (Grant No. 2019JM-579), Key Laboratory of Science and Technology innovation project of Shaanxi Province (Grant No. 2014SZS20-Z01, No. 2014SZS20-P05) and the Open Research Fund Program of Shaanxi Key Laboratory of Non-Traditional Machining (Grant No. 2015SZSj-61-6).

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Authors and Affiliations

  1. School of Mechatronics Engineering, Xi’an Technological University, 710021, Xi’an, People’s Republic of China

    Kaige Zhai, Lin Tang, Jia Liu, Xinyun Zhang, Yongning Yan & Xin Feng

Authors
  1. Kaige Zhai
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  2. Lin Tang
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  3. Jia Liu
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  4. Xinyun Zhang
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  5. Yongning Yan
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  6. Xin Feng
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Contributions

Kaige Zhai was the main contributor to the manuscript, and Lin Tang is the corresponding author of this manuscript. Under the guidance of Professor Lin Tang, Kaige Zhai, Yongning Yan and Xin Feng proposed the rotating magnetic field–assisted electrochemical machining method, designed the cathode structure and carried out the simulation study of gap flow field. Jia Liu and Xinyun Zhang participated in the rotating magnetic field–assisted electrochemical machining experiment and guided the manuscript writing.

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Correspondence to Lin Tang.

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Zhai, K., Tang, L., Liu, J. et al. Study on improving the surface roughness of multi-stage internal cone hole by rotating magnetic field assisted electrochemical machining. Int J Adv Manuf Technol 115, 1227–1236 (2021). https://doi.org/10.1007/s00170-021-06930-w

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