Mechanism Design of Magnetic-Assistance in Surface Finishing of End- Turning

A new mechanism design using a magnetic force with high efficiency to assist discharging dregs out of the electrode gap during the electrochemical finishing on the surface finish process that follows end-turning is investigated in the current study. Through simple equipment attachment, magnetic-assistance during electrochemical finishing can follow the cutting process on the same machine. This process can be used for various end-turning operations. Among the factors affecting electrochemical finishing, the magnetic-assistance is primarily discussed. The experimental parameters are chemical composition and concentration of the electrolyte, flow rate of the electrolyte, initial gap width, current rating, on/off period of pulsed current, feed rate of workpiece, rotational speed of workpiece and electrode, magnetic strength, and distance between the two magnets. A higher current rating with magnetic-assistance reduces the finishing time and avoids the difficulty of dreg discharge. Providing a large magnetic field intensity or using a small distance between the two magnets produces a larger magnetic force and discharge ability and better finishing. A large rotational speed of the workpiece and electrode produces better finishing. Pulsed direct current can slightly promote the effect of electrochemical finishing, but the current rating needs to be increased. The magnetic-assistance during the electrochemical finishing process makes a great contribution in a short time by making the surface of the workpiece smooth and bright.