電解式混氣電化學噴射微加工之研究;Research on Electrolytic Mixed Gas Electrochemical Jet Micro Machining

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Please use this identifier to cite or link to this item: http://ir.lib.ncu.edu.tw/handle/987654321/93869

Title:	電解式混氣電化學噴射微加工之研究;Research on Electrolytic Mixed Gas Electrochemical Jet Micro Machining
Authors:	舒慶哲;Su, Ching-Che
Contributors:	機械工程學系
Keywords:	電化學噴射加工;電解式混氣模組;微槽特徵;Electrochemical jet processing;Electrolytic mixed gas module;Micro concave
Date:	2023-08-19
Issue Date:	2024-09-19 17:43:52 (UTC+8)
Publisher:	國立中央大學
Abstract:	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.
Appears in Collections:	[Graduate Institute of Mechanical Engineering] Electronic Thesis & Dissertation

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