A design electromagnetic system of surface finishing processes

Abstract

An intelligent design system was created that efficiently uses a magnetic force to assist in the discharge of the dregs from the electrode gap during electrochemical finishing of cylindrical surfaces. In the current experiment, the author used a cylinder-shape electrode supplied with a continuous and pulsed direct current in the electrochemical finishing. This study used Taguchi's Method to analyze the combination of optimal parameters. The experimental parameters use four factors and three levels to measure the surface roughness of the magnetic-assistance in the electrochemical finishing. These four factors include electric current density, magnetic strength, distance between the two magnets, and rotational speed. For the design system, a high electric current density coupled with electromagnetic-assistance reduces the finishing time and mitigates the issues associated with dreg discharge. A small distance between two electromagnets or a large electromagnetic field produces a larger electromagnetic force enhancing the dreg discharge and subsequently improves the finish. A small tool-electrode diameter enhances electromagnetic-assisted electrochemical finishing. The average effect of the magnetic assistance was greater than the pulsed current while the machining time did not need to be prolonged by the off-time.