Experimental study of the effect of ultrasonic waves on the parameters of the electrochemical deburring process

Electrochemical deburring is a common method for removing small and micron scale turning additives. This study investigated the impact of ultrasonic waves on the parameters of the electrochemical deburring process. The parameter of material removal rate was investigated in two cases with and without the use of ultrasonic waves. Electric current, electrolyte temperature and ultrasonic power were input variables and other process parameters were considered constant. In the experiments, electrolyte of 6 liters of water and 20 grams of sodium nitrate, an ultrasonic transducer with a frequency of 28 kHz and a workpiece made of brass alloy C86300 were used. According to the results, the material removal rate increases with an increase in electric current in both cases without and with ultrasonic and remains constant after applying a specific current. where ultrasonic waves were applied, the material removal rate in the current of 2.7 and 2 amps increases from 20 to 100%, respectively, compared to the case without applying ultrasonic waves. The investigation examined the changes in the electric current as temperature increases from 25 °C to 40 °C in both in both mentioned cases. The results showed that the increase in temperature in both cases leads to an increase in electric current. Also, at any given temperature, the amount of increase in electric current in the state with the application of ultrasonic waves is greater than in the case without ultrasound, and the highest increase in the electric current has occurred by 40% for a temperature of 25 ℃.