الفهرس | Only 14 pages are availabe for public view |
Abstract The objective of the present research is to reveal the capability of adapting a small lathe to an electrochemical turning machine and adding a small mechanism for rotating electrode, Also the use of segmented tool for pulsating current without the need for using pulsed current generator for improving the accuracy and the performance of the process. A theoretical analysis for estimating the allowable feed rate has been presented to explain the mechanism of the process. Equations for predicting current density and metal removal rate in machining zone have been also derived. A locally adapted test lathe has been constructed for performing experimental tests. The experiments were divided into two groups, the first group has been performed for electrochemical turning with rotating electrode (ECTRE) and the second group has been performed for pulsed electrochemical turning with rotating electrode PECT-RE. The central composite second order rotatable design (CCD) has been utilized to design the experiments and response surface methodology (RSM) has been also employed to develop the experimental models. Analysis of machining characteristics of ECT has been submitted based on the developed models. In ECT-RE the effect of working parameters namely; applied volt, feed rate, tool workpiece speed ratio and tool diameter on metal removal rate (MRR), surface roughness (RA) and roundness error (RE) have been analyzed through RSM. In PECT-RE the effect of working parameters namely; applied volt, feed rate, tool workpiece speed ratio and current frequency on MRR, surface roughness, and roundness error have been analyzed through RSM. Comparisons between ECT and PECT responses lave been performed. |