秦歌,李蒙,李永亮,明平美,张新民,韩磊,闫亮,郑兴帅,牛屾.线阴极滚印式掩膜电解加工微坑阵列试验研究[J].表面技术,2023,52(7):261-269.
QIN Ge,LI Meng,LI Yong-liang,MING Ping-mei,ZHANG Xin-min,HAN Lei,YAN Liang,ZHENG Xing-shuai,NIU Shen.Experimental Study of Electrolytic Machining Process for Micro-pit Array on Workpiece Surface Using Linear Cathode and Rolling Printing Mask[J].Surface Technology,2023,52(7):261-269 |
| 线阴极滚印式掩膜电解加工微坑阵列试验研究 |
| Experimental Study of Electrolytic Machining Process for Micro-pit Array on Workpiece Surface Using Linear Cathode and Rolling Printing Mask |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.07.023 |
| 中文关键词: 线阴极 滚印式 掩膜电解加工 多种型面 微坑阵列 定域性 |
| 英文关键词:linear cathode rolling printing type mask electrochemical machining various shapes micro-pit array localization |
| 基金项目:国家自然科学基金(51105134);河南省基础与前沿研究项目(162300410025);河南省重点研发与推广专项(222102220001);河南理工大学校内博士基金(B2013-031) |
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| Author | Institution |
| QIN Ge | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| LI Meng | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| LI Yong-liang | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| MING Ping-mei | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| ZHANG Xin-min | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| HAN Lei | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| YAN Liang | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| ZHENG Xing-shuai | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
| NIU Shen | School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo 454000, China |
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| 中文摘要: |
| 目的 为了解决现有电解加工技术中难以使用同一装置在多种型面零件表面一次性大面积制备高精度微坑阵列的现状。方法 提出一种可用于多种型面零件批量加工微坑阵列的线阴极滚印式掩膜电解加工技术，设计了一种滚筒式掩膜复合线阴极的阴极工具装置，采用铜丝(直径500 μm)作为阴极，图形化的聚氯乙烯(PVC)作为掩膜，在10% NaNO3电解液、0.1 mm极间间隙条件下，在不锈钢304材料工件表面进行电解微坑试验，探究电压、阴极工具旋转速度、阴极尺寸对加工微坑阵列形貌的影响，通过超景深显微镜、扫描电子显微镜以及奥林巴斯显微镜对电解后的工件试样表面进行表面微观形貌观测。结果 选用10.5 V的电压、0.2 r/min的旋转速度可在工件表面加工出高精度、高一致性的微坑阵列，其微坑直径分布范围为402.8~ 440.3 μm，深度范围为66.2~74.2 μm，微坑粗糙度范围为0.42~0.83 μm。与传统的圆环型阴极电解加工结果对比，线阴极电解加工出的微坑阵列直径偏离掩膜孔尺寸小、定域性高。结论 使用线阴极滚印式掩膜电解加工方法可在不锈钢304材料工件平面、内圆柱面及外圆柱面制备大批量、高精度、高一致性的微坑阵列。 |
| 英文摘要: |
| To solve the problem that microstructure arrays is machined on the curved surface of parts, an electrochemical machining process with a linear cathode and a soft mask on a roller was proposed and used to machine micro-pit arrays on various surfaces of metal parts. An electrolytic system with a rolling printing mask was built and a rolling tool was designed. In this device, a copper linear (with diameter of 500 μm) was used as the cathode and a polyvinyl chloride (PVC) film with micro-hole arrays was used as the mask. The experiments were carried out on the surface of the 304 stainless steel workpiece under conditions of 10% NaNO3 electrolyte and 0.1 mm electrode gap. The effects of the voltage, the rotation speed of the cathode tool, and the cathode size on the morphology of micro-pit arrays were explored. The surface morphology of micro-pits on the workpiece was observed by ultra-depth field microscope, scanning electron microscope and Olympus microscope after the electrochemical machining process. The results showed that the micro-pit arrays on the surface of the workpiece could be machined and had high precision and high consistency under the electrolytic condition of 10.5 V processing voltage and 0.2 r/min rotation speed. The diameters of the micro-pits were in the range of 402.8-440.3 μm, the depth of them was between 66.2 μm and 74.2 μm, and the roughness range of the micro-pit was 0.42-0.83 μm. Compared with the electrolytic results using the traditional circular cathode, the diameter of the micro-pits produced by this electrochemical machining process with the linear cathode was reduced by about 100 μm, and the depth of the micro-pits was reduced by about 20 μm. The reason for this result was that the size of the linear cathode was so small and close to the size of the micro-hole on the mask, and the current density was concentrated mainly in the metal surface of the micro-holes on the mask during the electrolysis process, and there was no current distribution outside the processing area. However, because the size of the traditional circular cathode was much larger than that of the micro-hole on the mask and this circular cathode had a large range of the electric field distribution, the unprocessed area and the processed area of the workpiece surface were completely exposed to the electric field generated by the circular cathode in the electrochemical machining process. The redundant current distribution would cause micro corrosion or secondary corrosion on the unprocessed and the processed area, which lead to the deviation of the micro-pits diameter from the micro-hole on the mask and the poor localization of the micro-pit arrays. Furthermore, a large number of the micro-pit arrays were machined. The inner and the outer surfaces of the cylinder of 304 stainless steel workpiece were treated by the process and the device proposed in this paper. The experiment results shows that the electrochemical process with the linear cathode and the rolling printing mask has a significant and promising potential competitiveness in machining high-quality and high-precision microstructures on various surfaces of the metal parts. |
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