Optimization of Electrodeformational Surfacing by a Flexible Tool on the Basis of Experimental Design
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mization of Electrodeformational Surfacing by a Flexible Tool on the Basis of Experimental Design M. A. Levantsevicha, *, E. V. Pilipchuka, N. N. Maksimchenkoa, L. S. Belevskiib, and R. R. Demab aJoint
Institute of Mechanical Engineering, Belarus Academy of Sciences, Minsk, Belarus bNosov Magnitogorsk State Technical University, Magnitogorsk, Russia *e-mail: [email protected] Received March 13, 2019; revised September 20, 2019; accepted October 15, 2019
Abstract—Experimental and statistical models are developed for the formation of composite chromium coatings by electrodeformational surfacing using a flexible tool. By that means, the parameters needed for the production of coatings of the required thickness and roughness may be identified. Keywords: electrodeformational surfacing, flexible tool, composite coatings, experimental design, noncomposite design, surface roughness DOI: 10.3103/S1068798X20080158
In manufacturing, it is important to decrease product costs so as to improve competitiveness. One way of achieving this is to adopt new technologies such that, on switching between mass production, large-scale production, and small-scale production, performance matching that of traditional technologies may be attained [1, 2]. For example, electrolytic chromium plating, which is widely used in manufacturing to improve product performance and restore the size and shape of worn components, is valuable in large-scale and mass production when coatings are produced in large batches of largely identical products. However, in small-scale and one-off production—with the production of small batches once every two months, say— galvanic chrome plating is much less suitable, since the cost per unit of plated surface area greatly increases. Analysis of coating application shows that chromium layers may be applied by electrodeformational surfacing using a flexible tool, whose primary benefit is its simplicity [3–7]. In cladding by means of a flexible tool, electrical voltage is supplied to the frictional contact zone of the metallic brush and the coating. That heats the coating and intensifies the capture and adhesion of microparticles on the tip of the brush filaments, intensifying their transfer to the surface being coated. The thickness and surface roughness of the coating applied by electrodeformational surfacing using a flexible tool depend on the current at the coating–brush contact, the number of brush passes over the surface, and the speed of brush rotation. In practice, the required coating thickness is obtained by repeated change in the treatment conditions. However, this
requires considerable expenditures of materials and time, while the surfacing conditions employed are often far from optimal. Therefore, we need to study the conditions in which coatings are formed during electrodeformational surfacing using a flexible tool. In the present work, we determine the optimal electrodeformational surfacing conditions so as to produce a high-quality chromium-composite coating of the required thickness and surface roughness.
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