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Study of micro-bulges texture preparation in ultrasonic rolling pulse electrochemical micromachining

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Abstract

High efficiency and high quality machining of micro-bulged arrays on metal surfaces is a major technical challenge in the field of modern industry. In this paper, ultrasonic rolling pulse electrochemical micromachining (URPEMM) technology is proposed to prepare micro-bulged arrays on 304 stainless steel. Focusing on the widely used circular micro-bulges, distributions of electric field, temperature field and evolution processes of the circular, square and triangular sectional micro-bulges in URPEMM were analyzed by finite element analysis method(FEM). The simulation process of micro-bulges forming was experimentally verified. The results show that the current density and temperature increase first and then decrease, and the error between the experimental and simulation results of the micro-bulges is within 10%. The array micro-bulges with a diameter of 503.3 μm, a height of 33.5 μm, a roughness of 0.216 μm, and a microhardness of 305 Hv can be prepared in URPEMM. Furthermore, the surface tribological properties of circular micro-bulges decreases first and then increases with the increase of micro-bulged height, which was obtained through friction and wear tests, and the friction coefficient is minimum when the micro-bulged height is 10 μm.

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Data availability

The data used to support the fndings of this study are available from the corresponding author upon request.

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Funding

This project was supported by the National Natural Science Foundation of China (Grant No. 51975532) and the Zhejiang Provincial Natural Science Foundation (Grant No. LY19E050007).

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Authors and Affiliations

  1. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, Zhejiang, China

    Minghuan Wang, Wenjun Liu, Xin Heng, Ming Lv & Xuefeng Xu

  2. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education & Zhejiang Province, Zhejiang University of Technology, 288, Liuhe Road, Hangzhou, 310023, Zhejiang, China

    Minghuan Wang & Xuefeng Xu

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  1. Minghuan Wang
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  2. Wenjun Liu
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  3. Xin Heng
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Contributions

Minghuan Wang: paper writing, proofreading of paper content. Wenjun Liu: simulation, paper writing, data compilation, fgure production. Ming Lv: article translation and proofreading. Xin Heng, Xuefeng Xu: article typesetting and format modification.

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Correspondence to Minghuan Wang.

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Wang, M., Liu, W., Heng, X. et al. Study of micro-bulges texture preparation in ultrasonic rolling pulse electrochemical micromachining. Int J Adv Manuf Technol 130, 2785–2798 (2024). https://doi.org/10.1007/s00170-023-12815-x

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  • DOI: https://doi.org/10.1007/s00170-023-12815-x

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