Study of micro-bulges texture preparation in ultrasonic rolling pulse electrochemical micromachining

• Published in: International journal of advanced manufacturing technology 2024, Vol.130 (5-6), p.2785-2798
• Main Authors: Wang, Minghuan, Liu, Wenjun, Heng, Xin, Lv, Ming, Xu, Xuefeng
• Format: Article
• Language: English
• Subjects: Arrays; CAE) and Design; Coefficient of friction; Computer-Aided Engineering (CAD; Electric fields; Engineering; Finite element method; Height; Industrial and Production Engineering; Machining; Mechanical Engineering; Mechanical properties; Media Management; Metal surfaces; Microhardness; Micromachining; Original Article; Temperature distribution; Tribology
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-12815-x

High efficiency and high quality machining of micro-bulged arrays on metal surfaces is a major technical challenge in the field of modern industry. In this paper, ultrasonic rolling pulse electrochemical micromachining (URPEMM) technology is proposed to prepare micro-bulged arrays on 304 stainless steel. Focusing on the widely used circular micro-bulges, distributions of electric field, temperature field and evolution processes of the circular, square and triangular sectional micro-bulges in URPEMM were analyzed by finite element analysis method(FEM). The simulation process of micro-bulges forming was experimentally verified. The results show that the current density and temperature increase first and then decrease, and the error between the experimental and simulation results of the micro-bulges is within 10%. The array micro-bulges with a diameter of 503.3 μm, a height of 33.5 μm, a roughness of 0.216 μm, and a microhardness of 305 Hv can be prepared in URPEMM. Furthermore, the surface tribological properties of circular micro-bulges decreases first and then increases with the increase of micro-bulged height, which was obtained through friction and wear tests, and the friction coefficient is minimum when the micro-bulged height is 10 μm.