Ultrasonic-aided Electrochemical Finishing of female screw using completely inserted electrode

An effective system of ultrasonic-aided electrochemical finishing using low cost design electrodes for a female screw is developed. The process can be integrated with the primary processes of traditional turning, tapping, or rolling to achieve a good surface finish for screw threads. In the experiment, ultrasonic energy is transmitted to the electrolyte to assist the dregs discharge during polishing process. Four types of design electrode are completely inserted and put through both continuous and pulse direct current. It was found that the electrode with one side plate performs better than one with both sides. An electrode with one side plate with short width of plate provides larger discharge space and produces the best polishing effect. The average effect of the ultrasonics is found to be more effective than the use of pulsed current, without sacrificing the polishing time. The ultrasonic-aided electrochemical finishing needs quite a short period of time to make the surface of the female screw smooth and bright.