Milling performance of titanium alloy based on short electric arc machining with direct current power source

Liu, Kai; Zhou, Jianping; Zhou, Zijun; Xu, Yan; Hu, Guoyu; Zhang, Li; Song, Dan

doi:10.1007/s00170-020-05937-z

Cited by 22 publications

(5 citation statements)

References 21 publications

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“…Higher electrode speeds are more likely to break the arc, leading to unstable burning and ultimately insufficient energy input, which wears out the electrode and workpiece and increases the electrode loss. 24 Nevertheless, as Figure 7(c) shows, negative motor loss occurs at a milling depth of 6 mm, which is because the energy input is larger and more concentrated under the argon–water medium, and the waste chips are not discharged from the gap in time and adhere to the surface of the electrode, leading to negative motor pole loss. Although air has a higher dielectric strength than most other materials and is less sensitive to changes in the discharge gap when employed as a dielectric, there is not much difference between the REWRs of air at 30–25 V.…”

Section: Resultsmentioning

confidence: 99%

Study on the effect of air and argon assisted short electric arc machining on Ti6Al4V titanium alloy

Zhao

Zhou

Zhang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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The use of an argon–water medium rather than air–water medium is proposed to increase the material removal rate (MRR) and decrease surface oxide production for short electric arc machining. To provide a more stable discharge state during high-temperature processing, this approach uses argon to reduce the production of highly resistant refractory materials (e.g. titanium oxide). For short-arc machining of Ti6Al4V titanium alloy, the effects of the voltage, milling depth, electrode speed and gas flow rate on the MRR, relative electrode loss rate and surface roughness were compared for air–water and argon–water mixtures. It was discovered that the milling depth and voltage had the greatest impact on the MRR, voltage and electrode rotational speed had the greatest impact on the relative tool electrode wear rate (REWR), and voltage had the greatest impact on the surface roughness. In contrast to the air–water mixture, the MRR with the argon–water working medium was as high as 9391 mm3/min, with a 13% improvement in MRR, as well as a smooth and flat surface of the machined workpiece. Nevertheless, the REWR increased to 2.46% and the surface roughness was at least 432 μm with the argon–water medium, increasing by 59 μm compared with the air–water medium. Moreover, the addition of argon reduced the types of surface compound on the workpiece and decreased the residual stress defects, including the recast layer, microcracks and holes.

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Section: Resultsmentioning

confidence: 99%

Study on the effect of air and argon assisted short electric arc machining on Ti6Al4V titanium alloy

Zhao

Zhou

Zhang

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Zhou [18] proposed a novel modulated SEAM method and analyzed the effects of different process parameters on the machining performance via the MRR, the REWR, the speci c energy consumption and the surface roughness. Liu [19] proposed a machining method using a DC power supply instead of a pulse power supply to improve the MRR and reduce the REWR and speci c energy consumption in SEAM. The nal MRR reached 60,000 mm 3 /min, the REWR was 1.7%, and the energy consumption ratio was 36.6 Kj/cm 3 .…”

Section: Introductionmentioning

confidence: 99%

High speed short electric arc deep hole drilling experimental study based on tube electrode

Hu,

Fu,

Zhang

et al. 2024

Preprint

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To improve the machining efficiency and dimensional accuracy of deep hole drilling, a novel and efficient method of short electric arc drilling (SEAD) by tube electrode is proposed. However, due to the mismatch between excessive arc discharge energy and feed rate, efficient and high dimensional accuracy deep hole machining is fraught with difficulties. This paper reveals the SEAD mechanism based on pulsed power supply, and analyzes the voltage-current waveform and cross-section topography. In addition, the effects of different electrode polarity, voltage, pulse frequency, duty cycle and electrode feed rate on the material removal rate (MRR), relative electrode wear ratio (REWR), average diameter, taper and thickness of the recast layer are also investigated. Finally, an optimum parameters combination was obtained through process parameters optimization experiments, which confirmed the SEAD machining performance. The experimental results show that the SEAD achieved the highest MRR of 369.02 µm/s and the machining time was only 121.91 s with the optimal process parameters. The average diameter of the machined deep hole was 1264.56 µm, the depth was 44.99 mm, and the depth-to-diameter ratio was 35.57.

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“…They further revealed the machining mechanism by analyzing the surface morphology and chemical composition changes. Liu et al [12] studied the impact of the tool electrode polarity and voltage on titanium alloys under DC short arc milling. They deduced that the negative electrode machining can produce higher machining e ciency.…”

Section: Introductionmentioning

confidence: 99%

Milling performance of Ti2AlNb by DC short electric arc machining based on different electrode materials

Yin

Zhou

Chen

et al. 2023

Int J Adv Manuf Technol

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In this paper, a novel e cient and sustainable electrical discharge machining method, referred to as short electric arc machining (SEAM), is proposed to solve the problems of low e ciency, severe tool wear, and high cost of Ti2AlNb machining by traditional methods. The mechanism of SEAM with different voltages and tool electrode materials (W70Cu30, high-purity graphite, copper-plated graphite, and 304 stainless steel) is studied using a DC power supply, and the workpiece material removal rate (MRR), surface roughness (Sa), and relative tool wear rate (RTWR) are analyzed. In addition, the surface morphology, cross-sectional morphology, elemental distribution, and microhardness of Ti2AlNb after processing are investigated. The experimental results show that under 28 V, the W70Cu30 electrode achieves the highest MRR of 2571 mm 3 /min, which is higher than that of the other three electrode materials. It has also the lowest RTWR of the electrode and a relative electrode loss of only 0.0974%. The lowest surface roughness and heat affected layer of the workpiece after machining are 53.2 µm and 56.54 µm, respectively. The absolute difference of the width of the cross-section of the workpiece is the smallest, and the hardness of the recast layer of the workpiece is close to the hardness of the base metal, which is conducive to further processing. the thickness of the workpiece heat affected layer after machining with copper-plated graphite and 304 stainless steel electrodes is 64.6 µm and 72.4 µm, respectively.(5) The EDS analysis shows that after SEAM, a large amount of carbon, oxygen, and metal elements adheres to the workpiece surface, which indicates that after carburization and oxidation of the workpiece material, the tool electrode material and the conductive medium occur. The surface hardness of the workpiece machined by both high-purity graphite and copper-plated graphite electrodes signi cantly increases. Finally, the hardness values gradually decrease with the increase of the surface depth.

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Milling performance of titanium alloy based on short electric arc machining with direct current power source

Cited by 22 publications

References 21 publications

Study on the effect of air and argon assisted short electric arc machining on Ti6Al4V titanium alloy

Study on the effect of air and argon assisted short electric arc machining on Ti6Al4V titanium alloy

High speed short electric arc deep hole drilling experimental study based on tube electrode

Milling performance of Ti2AlNb by DC short electric arc machining based on different electrode materials

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