| 摘要: | 眾所周知於電化學混氣噴射加工法混入適當的氣泡量，可以使加
工中電解液與材料的接觸面積減小，相對單位面積電流密度提高，具
有特徵孔徑減小與表面粗糙度下降等優勢，能有效提高特徵精度與提
升表面品質。本論文採用新式電解混氣噴射電化學加工技術，其在電
解液流入噴嘴前，先經過電解產氣模組進行電解氣體混合生成處理，
在氣泡與電解液均勻混合後由微電極噴嘴射出，使混有氫氣與氧氣之
電解液噴射於不銹鋼工件表面，並施以電解電壓而加工製作出特徵微
結構。於研究過程中探討不同電解噴射加工參數與不同電解混氣比例
對加工特徵之影響。
在電解式混氣加工製程中，可控制電流而達到精確控制氣泡之尺
寸與混氣之比例，使加工中流場穩定，不會因混氣氣泡尺寸過大造成
氣泡堆積堵塞於流道內。且加工中控制氣泡比例可避免氣泡過多造成
電導率不足、材料移除率減少、流場混亂、表面粗糙度上升等問題。
實驗中所使用電解式混氣氣泡尺寸範圍控制在 7~13 μm，混氣比例則
是控制在 0.01~0.07 %之間。實驗結果發現，在高電流密度下，電解液
混氣後能夠使總體電流密度減少得而到較好的表面粗糙度且提高了加
工精度。且從實驗結果得知混氣電流與加工特徵直徑、深度、材料移
除量成反比，在本研究設定範圍內混氣電流值越大則上述之特徵值越
小。對於表面形貌而言，在加工電壓為 200 V、電解液濃度 12 wt.%、
加工間隙 450 μm、混氣電流 0.2 A、加工時間為 2 秒時，與未混氣加
工特徵相比，具有較佳的表面粗糙度。
;It is well known that by incorporating an appropriate amount of bubbles in
the mixed gas electrochemical jet processing method, the contact area between
the electrolyte and the material during processing can be reduced. This leads to
an increase in the current density per unit area, resulting in advantages such as
reduced characteristic size and decreased surface roughness of machined micro
concave. This technique effectively improves feature accuracy and enhances
surface quality. In this study, a novel mixed gas electrochemical jet processing
technique was adopted. Prior to entering the nozzle, the electrolyte undergoes
electrolytic gas mixing and generation treatment in an electrolytic gas
generation module. After uniform mixing of bubbles and electrolyte, the
mixture is ejected onto the surface of the stainless steel workpiece through a
microelectrode nozzle. By applying an electrolytic voltage, characteristic
microstructures are fabricated. The study investigates the influence of different
electrochemical jet processing parameters and various electrolyte gas mixing
ratios on the processed features.
In the electrolytic gas-liquid mixing machining process, the bubble size and
gas-to-liquid ratio can be precisely controlled by manipulating the current. This
ensures a stable flow field during processing, preventing blockages in the flow
channel due to excessively large gas bubbles. Moreover, controlling the bubble
ratio during processing prevents issues such as insufficient conductivity,
reduced material removal rate, turbulent flow field, and increased surface
roughness caused by an excessive number of bubbles.
In this study, the size of the electrolytic gas bubbles was maintained within
the range of 7 to 13 μm, while the gas-to-liquid ratio was controlled between
III
0.01% and 0.07%. The experimental results revealed that under high current
density, mixing the electrolyte gas reduced the overall current density and led
to improved surface roughness and machining accuracy. Additionally, the
experimental results indicated an inverse relationship between the mixing
current and machining characteristics such as diameter, depth, and material
removal rate. Within the set range of mixing current values in this study, larger
mixing currents corresponded to smaller values of these machining
characteristics.
Regarding surface morphology, at a processing voltage of 200 V, electrolyte
concentration of 12 wt.%, processing gap of 450 μm, mixing current of 0.2 A,
and a processing time of 2 seconds, the surface exhibited better roughness when
compared to characteristics from non-mixed processing. |
