SURFACE ROUGHNESS DECREASE IN THE ELECTROCHEMICAL-ULTRASONIC HYBRID MACHINING

Abstract

The paper deals with the presentation of a method for numerical modeling and simulation of the effect of the ultrasonic component in the electrochemical-ultrasonic hybrid machining. The focus is on removing surface microgeometry peaks beneath the passivated layer and the surface smoothing mechanism. A shear fatigue resistance calculation was performed for C120 steel. After defining the input parameters, the numerical modeling and simulation were conducted using the specialized software program Comsol Multiphysics. A scanning electron microscope analysis of the processed surfaces was carried out, followed by a study of the influence of each machining parameter (current density, ultrasonic power, machining time).