Design of compound processes of electrochemical finishing and rolling-levelling following turning

Abstract

A new finishing method that uses an effective electrode and a nonconductive roller to execute the design of compound processes of electrochemical finishing and rolling-levelling following turning is investigated. The submitted processes can be used for various turning operations. Through simple equipment attachment, electrochemical finishing and rolling-levelling can follow to execute the finishing process on the same machine. Among the factors affecting electrochemical finishing, the performance of rolling-levelling combined with electrochemical finishing is primarily discussed. In the experiment, the electrode is used with continuous and pulsed direct current. The experimental parameters are feed rate of electrode and roller, rotational speed of the workpiece, die material, electrical current rating, pulsed period, roller geometry, and electrode geometry. An adequate workpiece rotational speed produces better finishing. The design change of the electrode from a semicircle to a wedge-form with small end radius causes the electrolytic products and heat bringing away more rapidly and performs the best finishing. The finishing effect of pulsed direct current is slightly better than using continuous direct current. However, the use of pulsed current raises the machining time and cost. An effective and low-cost finish process through the design electrode and using the rolling-levelling assistance in the electrochemical finishing after the turning process make the surface of the workpiece smooth and bright is presented.