Simulation Analysis and Experimental Validation of Cathode Tool in Electrochemical Mill-Grinding of Ti6Al4V

Abstract

Electrochemical mill-grinding (ECMG) is an ideal technical means to achieve an efficient and precise machining of titanium alloy monolithic structural parts. In the rough ECMG process, the selection of a reasonable cutting depth can improve the machining efficiency of the rough machining. Adopting a reasonable cathode tool structure can achieve a higher precision in the formation of the rough surface, reduce the finishing allowance and tool wear of subsequent finishing. With this aim, the present research proposed a cathode tool with a reasonable structure. Simulation results showed that the designed cathode tool presented a good uniformity of the flow field in the machining gap, which resulted in a higher precision in the formation of the rough surface. For experimental validation, a larger cutting depth and a designed cathode tool was employed to carry out the rough and finish machining experiments on a Ti6Al4V titanium alloy. The experimental results show that a good flatness of the sidewall of the rough-machining groove was obtained by this scheme. Furthermore, the machining surface exhibited no flow marks, and rough machining accounted for 92.37% of total removal. Moreover, measurement of the micro-morphology, roughness and elemental composition of the machined surface, and the effects of different machining parameters on the surface quality of titanium alloys, were studied.

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

“…The flow field of the liquid outlet at the center of the tool cathode is relatively concentrated. Because the liquid outlet is at the center of the circle, even if the tool cathode rotates at different angles, the high-flowrate area always acts on the center of the tool cathode [24]. In electrochemical machining, the flow field has a significant impact on the conductivity.…”

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

“…Zhang et al [ 28 ] developed a new chemical mechanical polishing method and slurry to further improve polishing performance for titanium alloys. Li et al [ 29 ] studied the electrochemical grinding (ECMG) process for titanium alloy, which can provide high-efficiency and precise machining of titanium alloy integral structural parts. Xiao et al [ 30 ] investigated the belt high-efficiency finishing (BEF) method to establish a material removal model to achieve the final precision-finishing of titanium alloy parts.…”

Flow field characteristics and experimental research on inner-jet electrochemical face grinding of SUS420J2 stainless steel

“…In terms of the tool structure, Pang et al 17 used a floating cathode to process the outer surface of GCr15 steel rotating parts, and established the relationship between the inter-electrode gap and the electrolyte pressure. Li et al 18 analyzed the fluid flow structure of the tubular grinding wheel based on the flow field simulation, and showed that the spiral fluid flow groove could improve the uniformity of the flow velocity in the lateral gap. In addition, the influence of different inner-jet grinding wheel structures on the flatness and the frontal gap distribution of the GH4169 alloy ECG was also studied 19 .…”