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A new design is investigated for a superfinishing module for freeform machining using magnetic assistance to help discharge dregs from the gap between the electrodes and the workpiece during electrochemical finishing and burnishing. The design of the finishing tool considered in the present study includes an electrode and a burnishing tool. The design of the magnetic-assistance system and the finishing tool are discussed, as well as their effect on the superfinishing processes. The experimental parameters are the initial gap width, the flow rate of electrolyte, the current density, and the pulse period. Different process configurations are also evaluated. Smaller distances between the two magnets or larger magnetic field intensities provide larger magnetic strength, discharge ability, and a better finish. Magnetic assistance can mitigate the difficult problem of dreg discharge associated with high current density, thus enabling a reduction in the finishing time. The average effect of the magnetic assistance was greater than that of pulsed current, while the machining time was not prolonged by the off time. A higher rotational speed of the magnets produced a better finish. The superfinishing module incorporating magnetic assistance in electrochemical finishing and burnishing requires only a short time to make a freeform surface smooth and bright, and eliminates the need for precise traditional polishing.
Journal of Vacuum Science & Technology B: Microelectronics and Nanometer Structures (Volume:27 , Issue: 3 )
Date of Publication: May 2009