Development of an electrochemical deburring process using ultrasonic waves for ‎combustion engine oil spring ring

Electrochemical deburring is one of the methods commonly used to remove machining inclusions on small and micron scales. High accuracy, speed, and possibility of deburring at the same time are the advantages of this electrochemical deburring method. In this article, the effect of applying ultrasonic waves on the electrochemical deburring process for combustion engine oil spring rings has been investigated. The effect of the input parameters ultrasonic power, electric current intensity, and electrolyte temperature on the output parameter of material removal rate in electrochemical deburring was investigated. The experiments were designed by the Response Surface method and based on the Box-Behnken design so that each of the three mentioned input parameters is changed in three levels and the other input parameters are kept constant. Two types of electrolytes used in these experiments are NaCl and NaNO3. The maximum applied ultrasonic power is one hundred watts. The results of the experiments showed that the effect of ultrasonic on the material removal rate under the same conditions of the maximum electrolyte temperature and the maximum electric current intensity for the oil spring ring in the case of using NaCl electrolyte is 83.87% and in the case of using NaNO3 electrolyte is 89.74%. Also, for the oil spring ring, the average increase in material removal rate for NaNO3 electrolyte compared to NaCl electrolyte is 19.6%. After the ultrasonic power, electric current intensity and electrolyte temperature, respectively, had a positive effect on increasing the rate.