| dc.description.abstract | When the array electrodes that are fabricated by wire electrical discharge machining used to fabricate the micro-cylindrical array electrodes by electrochemical machining, the electrolyte cannot be renewed by rotating multiple electrodes or designing the flow channels in the electrodes. This makes it difficult to process micro-cylindrical array electrodes with good electrode morphology and accuracy. To overcome the aforementioned difficulties, in this study, a new type of upward jet electrolyte supply fixture was designed. In the design, ultrasonic vibration-assisted microarray electrodes and microarray electrodes perform a reciprocating motion in the array hole of another copper electrode during the processing to conduct electrochemical fabricate micro-cylindrical array electrodes. The various machining parameters, such as machining time, working voltage, pulse off time, power of ultrasonic vibration, and effect on the various processing characteristics, were discussed, including electrode of morphology, average diameter, average diameter of electrode, average diameter range, average consumption length, average consumption of electrode, average consumption range, and diameter difference.
The experimental results show that the upward jet electrolyte supply type could obtain a higher electrolyte flow rate compared with the traditional downward jet electrolyte supply type. Further, the reciprocating motion of the microarray electrode could effectively reduce the influence of the tip effect of the electric field, and the ultrasonic vibration would produce pumping and cavitation effects to promote electrolyte renewal and remove electrolysis products. Through these above methods, the design will homogenize the electric field in the processing area, accelerate the electrolyte renewal, and quickly remove the reaction heat and electrolysis products in the processing area. Using this approach, compared to only upward jet flow assistance or ultrasonic vibration assistance independently, better electrode morphology and smaller average electrode diameter could be obtained. When the optimal combination of experimental parameters was a machining time of 7 s, working voltage of 9 V, pulse off time of 50 us, and power of ultrasonic vibration of Level 10, this resulted in an optimal average electrode diameter of 61.3 um, electrode consumption length of 122.3 um, and difference diameter of 5.4 um. As such, the proposed design can effectively improve the overall morphology of the electrode. | en_US |