Enhanced error correction for adaptive electrochemical machining of eccentric bushings

• Published in: International journal of advanced manufacturing technology 2024-11, Vol.135 (3-4), p.1319-1328
• Main Authors: Zhang, Zhixin, Fan, Shuangjiao, Li, Jingdong, Zhu, Xiaofei, Xu, Yunchao, Wang, Jikun, Pang, Guibing
• Format: Article
• Language: English
• Subjects: Bushings; CAE) and Design; Computer-Aided Engineering (CAD; Eccentricity; Effectiveness; Efficiency; Electric potential; Electrochemical machining; Engineering; Equivalence; Error analysis; Error correction; Error correction & detection; Industrial and Production Engineering; Mathematical models; Mechanical Engineering; Media Management; Original Article; Real time; Time measurement; Voltage; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-14614-4

s Aiming at the difficult problem that the ability of ECM error correction is limited by the noncontact machining mechanism and the change of machining gap is difficult to be measured in real time, a method is proposed to realize the enhanced adaptive correction of radial circular runout error by online voltage regulation so as to realize the improvement of the efficiency of the correction of ECM error under the conditions of smaller removal amount and normal machining gap. Taking the eccentricity error of the eccentric bushing parts as the radial circular runout error, adopting the equivalent resistance between poles (real-time voltage/real-time current) to indicate the machining gap, and taking the change of the equivalent resistance as the basis for real-time voltage adjustment, the mathematical model for the correction of the radial circular runout error is established. Comparison experiments between enhanced adaptive machining and constant pressure machining are carried out to verify the effectiveness of enhanced adaptive machining in correcting radial circular runout error. The efficiency of radial circular runout error correction by enhanced adaptive machining is improved by 60.0%, and the average workpiece removal is saved by about 40.7% compared to constant pressure machining at the same time. The experimental results of radial circular runout error after machining are in accordance with the expected results of the mathematical model. Through mathematical modeling and experimental research, it is confirmed that regulating the machining voltage to achieve enhanced adaptive correction of radial circular runout error can effectively improve the error correction accuracy and efficiency of difficult-to-machine rotary parts, and it is an effective method to solve the problem of radial circular runout error correction of eccentric parts.