Plane Machining by Inner-Jet Electrochemical Milling of TiB2/7050 Aluminum Matrix Composite

Abstract

Electrochemical milling (ECM) is an ideal technique for machining thin-walled structural parts of aluminum matrix composites. Adopting a reasonable tool cathode structure, feed rate, and processing method can improve the machining efficiency. In this study, a tool cathode with a reasonable structure was selected through flow field simulation. Then, the material removal rate (MRR) and surface roughness were studied using various ECM parameters. Finally, the transverse movement and processing method in which the starting position was rotated 90° were studied, and a plane of 59 × 59 mm was machined. The experimental results show that using an appropriate tool cathode can create a more uniform flow field. The MRR was 168.6 mm3/min and the surface roughness (Ra) was 3.329 µm at a feed rate of 30 mm/min. For machining larger plane structures, a transverse movement of 7 mm is verified to be the most suitable because of the best smoothness in the middle of the two processes. By using the same machining method and rotating the starting position 90°, the flatness of the processing plane decreased from 0.296 mm to 0.251 mm, a reduction of 15.2% compared to that obtained in the first processing.

Removal Mechanism and Electrochemical Milling of (TiB+TiC)/TC4 Composites

“…A higher current means more electrons are exchanged per unit of time, and anode metal atoms lose electrons easier, so the material removal rate rises significantly with an increasing voltage. This is also mentioned by researchers in the electrochemical machining of other materials [ 36 , 51 ].…”

“…When the feed rate is increased, the cathode sweeps across the anode surface at a faster rate, reducing the time for the electrolytic reaction to occur, so the depth of the grooves decreased. However, since a larger area is swept in the same amount of time, longer grooves are created, which in turn increases the MRR [ 36 ]. The effect of the feed rate on the material removal rate is not as pronounced as that of the voltage, but its effect on the surface roughness is significant.…”

“…Liu explored the electrochemical machining of TB6 titanium alloy in a NaNO solution and successfully produced grooves and flat surfaces by electrochemical milling [ 35 ]. He optimized the tool cathode structure, created a more uniform flow field in TiB/7050 Aluminum Matrix Composite electrochemical milling, and reduced the flatness of the processing plane by 15.2% [ 36 ]. Ma evaluated the electrochemical turning method (ECT) for TMCs and verified the practical performance of the intermittent feed ECT method for machining titanium matrix composites [ 37 ].…”

Effect of Vibration Direction on Two-Dimensional Ultrasonic Assisted Grinding-Electrolysis-Discharge Generating Machining Mechanism of SiCp/Al

“…Traditional grinding, milling, and other mechanical processing technologies cannot be processed efficiently and with high quality; however, ultrasonic-assisted processing technology, which is similar to “micro-grinding”, performs remarkably well on hard, brittle, and difficult-to-machine materials and can generate better workpiece surface quality while utilizing lower grinding force [ 3 , 4 , 5 , 6 ]. Electrolytic machining (ECM) is suitable for the processing of curved surfaces and tiny holes of conductive materials because of its non-contact force and high processing efficiency, but electrical discharge machining (EDM) is often selected for the processing of non-conductive materials [ 7 , 8 , 9 ]. Therefore, it is necessary to take full use of the advantages of various processing technologies, change the process method used, and utilize ultrasonic assistance in different vibration directions to improve the processing effect of composite materials [ 10 , 11 , 12 ].…”

The Design of Aluminum-Matrix Composites Reinforced with AlCoCrFeNi High-Entropy Alloy Nanoparticles by First-Principles Studies on the Properties of Interfaces

“…Those AMCs have great potential for applications in aviation, transportation, manufacturing, and some other industries. Ceramic nanoparticles, such as Al 2 O 3 , TiB 2 , TiC, SiC, which possess high mechanical strength and stiffness were firstly proposed and introduced into aluminum to fabricate the AMCs [5][6][7][8], whose mechanical properties are closely related to the interfacial wettability and bonding behaviors of interfaces between the ceramic reinforcements and the Al matrix. In general, poor wettability may result in weak bonding at the interfaces, and the brittle nature of some ceramics would lead to a poor strengthening effect and a large loss in plasticity in the AMCs [9,10].…”