The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining
Deterministic polishing based on jet electrochemical machining (Jet-ECM) is a stress-free machining method for low-rigidity and ultra-precision workpieces. The nozzle is equivalent to a special tool in deterministic polishing, and the workpiece material is removed using the mechanism of electrochemi...
| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-03-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/15/3/393 |
| _version_ | 1797239983053996032 |
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| author | Ke Wang Hongding Wang Yanlong Zhang Huirong Shi Jiahao Shi |
| author_facet | Ke Wang Hongding Wang Yanlong Zhang Huirong Shi Jiahao Shi |
| author_sort | Ke Wang |
| collection | DOAJ |
| description | Deterministic polishing based on jet electrochemical machining (Jet-ECM) is a stress-free machining method for low-rigidity and ultra-precision workpieces. The nozzle is equivalent to a special tool in deterministic polishing, and the workpiece material is removed using the mechanism of electrochemical dissolution at the position where the nozzle passes. By precisely regulating the nozzle’s movement speed and dwell time, the quantity of material removed from the workpiece at a designated position can be finely adjusted. With this mechanism, the improvement of the workpiece shape accuracy can be achieved by planning the nozzle trajectory and nozzle movement speed. However, due to the positioning errors of the polishing device, the actual position of the nozzle may deviate from the theoretical position, resulting in errors in material removal amount, which affects the accuracy and stability of the polishing process. This study established a mathematical model to analyze the influence of nozzle positioning errors in deterministic polishing based on Jet-ECM. This model has been used to design a specific deterministic polishing device based on Jet-ECM. With the proposed deterministic polishing device, the surface shape of the workpiece is converged. The surface peak-to-valley (PV) value of the φ 50 mm workpiece (valid dimensions = 90% of the central region) indicated that the shape error of the surface was reduced from 2.67 μm to 1.24 μm in 34 min. The power spectral density (PSD) method was used to evaluate the height distribution and height characteristics of the workpiece surface. The results show that the low frequency spatial error is reduced significantly after processing. This study improves the accuracy of the stress-free deterministic polishing methods and further expands the use of deterministic polishing in industry. |
| first_indexed | 2024-04-24T18:00:12Z |
| format | Article |
| id | doaj.art-30eaf1b35ed0468cb62a19e273aff046 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-04-24T18:00:12Z |
| publishDate | 2024-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-30eaf1b35ed0468cb62a19e273aff0462024-03-27T13:55:17ZengMDPI AGMicromachines2072-666X2024-03-0115339310.3390/mi15030393The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical MachiningKe Wang0Hongding Wang1Yanlong Zhang2Huirong Shi3Jiahao Shi4School of Mechanical Engineering, Lanzhou Jiaotong University, Lanzhou 730070, ChinaSchool of Mechanical Engineering, Lanzhou Jiaotong University, Lanzhou 730070, ChinaSchool of Mechanical Engineering, Lanzhou Jiaotong University, Lanzhou 730070, ChinaSchool of Mechanical Engineering, Lanzhou Jiaotong University, Lanzhou 730070, ChinaDepartment of Bioresource Engineering, McGill University, Montreal, QC H9X 3V9, CanadaDeterministic polishing based on jet electrochemical machining (Jet-ECM) is a stress-free machining method for low-rigidity and ultra-precision workpieces. The nozzle is equivalent to a special tool in deterministic polishing, and the workpiece material is removed using the mechanism of electrochemical dissolution at the position where the nozzle passes. By precisely regulating the nozzle’s movement speed and dwell time, the quantity of material removed from the workpiece at a designated position can be finely adjusted. With this mechanism, the improvement of the workpiece shape accuracy can be achieved by planning the nozzle trajectory and nozzle movement speed. However, due to the positioning errors of the polishing device, the actual position of the nozzle may deviate from the theoretical position, resulting in errors in material removal amount, which affects the accuracy and stability of the polishing process. This study established a mathematical model to analyze the influence of nozzle positioning errors in deterministic polishing based on Jet-ECM. This model has been used to design a specific deterministic polishing device based on Jet-ECM. With the proposed deterministic polishing device, the surface shape of the workpiece is converged. The surface peak-to-valley (PV) value of the φ 50 mm workpiece (valid dimensions = 90% of the central region) indicated that the shape error of the surface was reduced from 2.67 μm to 1.24 μm in 34 min. The power spectral density (PSD) method was used to evaluate the height distribution and height characteristics of the workpiece surface. The results show that the low frequency spatial error is reduced significantly after processing. This study improves the accuracy of the stress-free deterministic polishing methods and further expands the use of deterministic polishing in industry.https://www.mdpi.com/2072-666X/15/3/393stress-free polishingdeterministic polishingjet electrochemical machiningpositioning accuracysurface flatness |
| spellingShingle | Ke Wang Hongding Wang Yanlong Zhang Huirong Shi Jiahao Shi The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining Micromachines stress-free polishing deterministic polishing jet electrochemical machining positioning accuracy surface flatness |
| title | The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining |
| title_full | The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining |
| title_fullStr | The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining |
| title_full_unstemmed | The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining |
| title_short | The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining |
| title_sort | development of the stress free polishing system based on the positioning error analysis for the deterministic polishing of jet electrochemical machining |
| topic | stress-free polishing deterministic polishing jet electrochemical machining positioning accuracy surface flatness |
| url | https://www.mdpi.com/2072-666X/15/3/393 |
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