Development of electric rust preventive machining method

–Verification of the optimized rust prevention current and electrical characteristic with supporting electrode in grinding–

Abstract

Machining fluid containing various chemicals, including oil and extreme-pressure agents, etc., is used for conventional machining. This leads to high costs and harmful effects on the environment due to the discharge of large amounts of CO₂. In this investigation, the electric rust preventive machining method that uses only water as the machining fluid was developed to resolve the environmental problems. The supporting electrode was developed to achieve more effective rust prevention. Moreover, rust prevention of the electromagnetic chuck and workpiece and the optimized rust prevention current of the electromagnetic chuck and workpiece were verified using the supporting electrode. The results indicated that optimized rust prevention of electromagnetic chuck and workpiece could be achieved with a very low electrical power consumption of 0.62 W (0.1 A × 6.2 V, one workpiece, h20 mm pool electrode, and contact-type supporting electrode) to 2.0 W (0.2 A ×10 V, two workpieces, h20 mm pool electrode, and contactless-type supporting electrode).