ABSTRACT The use of nickel aluminum bronze (NAB) is found in components that include landing gear bearings, cast valve bodies, and perforated orifice for pharmaceutical industries. Machining of the NAB alloy in the micro-domain is a great challenge because of its unique mechanical and chemical properties. This work investigates the suitability of electrode materials for anodic dissolution of the NAB alloy through the use of the electrochemical micromachining process. Three distinct electrode materials, namely, brass, copper, and tungsten carbide were chosen for understanding the micromachining characteristics. The nature of the dissolution of NAB alloy and the impact of all three electrodes has been studied by varying the process parameters. Micro-hole making experiments were conducted by response surface methodology (RSM) based central composite design (CCD). The RSM-CCD utilizes quantitative process parameters for choosing qualitative electrode materials based on radial overcut, surface roughness, and material removal rate. SEM pictures examined the morphologies of the micro-holes. All the three electrodes exhibited successful anodic dissolution of NAB alloy under various parametric conditions. NAB alloy machined with tungsten carbide electrode exhibited the least radial overcut and surface roughness, whereas the copper electrode removed the highest materials. The brass electrode exhibited intermediate performance between tungsten carbide and copper electrodes.

中文翻译：

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镍铝青铜合金电化学微加工实验研究

摘要 镍铝青铜 (NAB) 用于包括起落架轴承、铸造阀体和制药行业的穿孔孔板在内的部件中。由于其独特的机械和化学性能，在微域中加工 NAB 合金是一个巨大的挑战。这项工作通过使用电化学微加工工艺研究了电极材料对 NAB 合金阳极溶解的适用性。选择了三种不同的电极材料，即黄铜、铜和碳化钨，以了解微加工特性。通过改变工艺参数，研究了 NAB 合金溶解的性质和所有三个电极的影响。微孔制作实验是通过基于响应面法（RSM）的中心复合设计（CCD）进行的。RSM-CCD 利用定量工艺参数根据径向过切、表面粗糙度和材料去除率选择定性电极材料。SEM图片检查了微孔的形态。所有三个电极在各种参数条件下都表现出 NAB 合金的成功阳极溶解。用碳化钨电极加工的 NAB 合金表现出最小的径向过切和表面粗糙度，而铜电极去除了最高的材料。黄铜电极表现出介于碳化钨和铜电极之间的中间性能。RSM-CCD 利用定量工艺参数根据径向过切、表面粗糙度和材料去除率选择定性电极材料。SEM图片检查了微孔的形态。所有三个电极在各种参数条件下都表现出 NAB 合金的成功阳极溶解。用碳化钨电极加工的 NAB 合金表现出最小的径向过切和表面粗糙度，而铜电极去除了最高的材料。黄铜电极表现出介于碳化钨和铜电极之间的中间性能。RSM-CCD 利用定量工艺参数根据径向过切、表面粗糙度和材料去除率选择定性电极材料。SEM图片检查了微孔的形态。所有三个电极在各种参数条件下都表现出 NAB 合金的成功阳极溶解。用碳化钨电极加工的 NAB 合金表现出最小的径向过切和表面粗糙度，而铜电极去除了最高的材料。黄铜电极表现出介于碳化钨和铜电极之间的中间性能。用碳化钨电极加工的 NAB 合金表现出最小的径向过切和表面粗糙度，而铜电极去除了最高的材料。黄铜电极表现出介于碳化钨和铜电极之间的中间性能。用碳化钨电极加工的 NAB 合金表现出最小的径向过切和表面粗糙度，而铜电极去除了最高的材料。黄铜电极表现出介于碳化钨和铜电极之间的中间性能。