| dc.description.abstract | Electrochemical machining (ECM) is one of the non-traditional manufacturing processes. The advantages of ECM include not being affected by the hardness and strength of the material,applicable to any metal material , fast processing speed and no surface residual stress, no heat zone and smooth workpiece surface. Furthermore , it has merits of lower price in equipments, mass production and lower costs, etc.Currently,it’s considered as one of the most promising industry.
Grey relational analysis (GRA) is a method of obtaining the most experimental results by limited experiments, and analyzing the influence of experimental parameters on the processing quality and finding the best combination of parameters, the advantage of GRA is that it could have multi-objective optimization. This study uses a self-designed metal mask, uses pure copper as a tool, stainless steel SUS301 sheet with a thickness of 0.1 mm as a workpiece, Perform TMEMM processing experiments to verify the feasibility of the metal mask. GRA is used to analyze the influences of parameters (e.g.: electrolyte concentration, applied voltage, diameter of the mask hole, and the thickness of the mask) on the undercut, uniformity and roundness of array holes, and estimate the best combination of parameters.
Through the experimental results, it can be found that the metal mask can be used in the electrochemical processing of the mask after the double-sided adhesive is used to increase the fit between the workpiece and the mask. The most important factors for the characteristics of finished products are diameter of the mask hole and thickness of the mask and the best parameter combination is A_3 B_3 C_2 D_1 (electrolyte concentration 16wt%, applied voltage 18V, diameter of the mask hole 1.2 mm, and the thickness of the mask 0.1mm). The processing results were as follows: the undercut was 0.07 mm, the average deviation was 0.04 mm, and the roundness error was 0.18 m. Compared with the original working condition (A1B1C1D1), the GRA is increased from 0.34 to 0.96. It is closed to the ideal working condition. | en_US |