Compound machining of titanium alloy by super high speed EDM milling and arc machining

Wang, Fei; Y, Liu; Zhang, Yanzhen; Tang, Zemin; Ji, Renjie; Zheng, Chao

doi:10.1016/j.jmatprotec.2013.10.015

Cited by 121 publications

(37 citation statements)

References 23 publications

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“…How to improve the surface quality is still a challenge to the arc discharge machining technology. Wang et al proposed to combine EDM and arc machining with a low discharge current to advance the surface quality when machining the difficult-to-cut materials titanium alloy and mold steel [16,17]. On the other hand, as a promising high-efficiency material removal process, although the negative BEAM demonstrated very high machining efficiency, the machining characteristics of the positive BEAM are not well investigated and understood yet.…”

Section: Introductionmentioning

confidence: 99%

Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining

Chen

et al. 2015

Int J Adv Manuf Technol

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A nickel-based high-temperature alloy widely used in aerospace engines is a typical difficult-to-cut material by conventional machining processes due to its high-temperature mechanical strength and toughness. Blasting erosion arc machining (BEAM), a new type of electrical discharge machining (EDM) method, is capable of removing such materials with a very high material removal rate and a low tool wear ratio. This paper presents experimental investigations in machining characteristics and machined surface integrity of the nickel-based alloy GH4169 (similar to Inconel718) by positive polarity blasting erosion arc machining (positive BEAM). The test results imply a possibility to improve the surface integrity with positive BEAM compared with a regular negative one. In this work, a three-factor, three-level machining performance experiment was carried out to examine the effects of the machining parameters such as discharge peak current, flushing inlet pressure, and pulse duration on the machining performances of material removal rate, tool wear ratio, and surface roughness. The experimental results show that positive BEAM is capable of greatly improving the machined surface integrity. The surface roughness decreased from 274 μm (under negative polarity BEAM) down to 31 μm (under positive polarity BEAM). Additionally, fewer micro-cracks and a thinner heat-affected zone on the workpiece surface can be observed. It also reveals that by optimizing the combination of the negative and the positive BEAM, favorable machining performances of high material removal rate and finer surface roughness are possible. By utilizing the polarity effects, the machining allowance for the subsequent semi-finishing processes such as cutting can be further reduced.

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Section: Introductionmentioning

confidence: 99%

Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining

Chen

et al. 2015

Int J Adv Manuf Technol

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“…When the peak current was 300 A, pulse duration was 2 ms, and pulse interval was 8 ms, the achieved MRR was 2400 mm 3 /min. Especially, when the peak current was 500 A, MRR could be 16, 800 mm 3 /min, and the specific energy efficiency was 33.6 mm 3 /(A · min) which was about 10 % higher than that reported in reference [23] (30.7 mm 3 /(A · min) and over 10 times of the EDM processing that reported in reference [2] (3.1 mm 3 /(A · min)). Also, the MRR can be over 2.5 times of that of the milling processing under its best performance (6236 mm 3 /min, based on the longest tool life and largest material removal rate) that reported in reference [8].…”

Section: Results Of Experimental Setmentioning

confidence: 53%

“…Besides, machining with different polarities appeared different surface characters. A possible reason for the results that mentioned in reference [23,26] is the differences in energy distribution between the anode and the cathode, the energy distributed to the anode is always greater than that to the cathode. When electrode polarity is positive, the energy distributed to the electrode increases, whereas the energy distributed to the workpiece decreases.…”

Section: Comparisons Of Machining Performancementioning

confidence: 98%

“…Compared to the EDM process, the arc discharge is endowed with higher energy density and is developing for processing the difficult-to-cut materials in recent years. Wang et al [23] reported a novel compound machining of titanium alloy by super high speed EDM milling and arc machining, the maximum MRR was 21,494 mm 3 / min (peak current 700 A), and the specific energy efficiency was 30.7 mm 3 /(A • min). The blasting erosion arc machining (BEAM) [24] is a low cost, high efficiency arc machining process which is based on hydrodynamic arc breaking mechanism rather than mechanical movement arc breaking mechanism.…”

Section: Introductionmentioning

confidence: 99%

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Study on blasting erosion arc machining of Ti–6Al–4V alloy

Chen

et al. 2015

Int J Adv Manuf Technol

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Blasting erosion arc machining (BEAM) was applied to improve the machining efficiency of Ti-6Al-4Valloy. 5-factor, 2-level fractional factorial experiment was firstly employed to find out the main factors for MRR (material removal rate). According to the results of fractional factorial experiment, 3-factor, 2-level full factorial experiment was conducted to find out the relationship between machining performance and the main factors (peak current, pulse duration, and pulse interval) under the negative electrode machining. Results revealed that when peak current was 500 A and pulse duration was 8 ms, MRR could achieve 16,800 mm 3 /min, which means the specific energy efficiency was 33.6 mm 3 / (A · min). Then, MRR was optimized base on MATLAB optimization toolbox and could reach 20,100 mm 3 /min when adopting the optimized parameters (peak current 600 A, pulse duration 8.8 ms, and pulse interval 3.0 ms). Although TWR (tool wear ratio) can be effected by the machining parameters, it appeared to be stable (around 3 ± 1 %). Besides, the polarity effect was also studied, and flow field simulations were employed to illustrate the influence of feeding direction on the surface roughness. In addition, the machined surface was analyzed by utilizing SEM, EDS, XRD, etc. Results of the surface analysis disclosed that the oxygen content in the negative electrode machined surface was obviously higher than that in the positive electrode machined surface. Since the positive electrode machined surface was much smoother, it can be used to improve the surface quality while the negative electrode machining is suitable for the bulk material removal with high energy. Finally, a Ti-6Al-4V turbine blade sample was machined to demonstrate the feasibility of high efficiency BEAM in difficult-to-cut material processing.

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“…It can be concluded that when current-voltage was increased, micro-cracks clearly appeared on the outer side of pit [36]. Meanwhile, a pit inner surface and depth revealed good performance with the ushing rate of electrolytic used as mentioned by Wang, such that the ushing rate has to be optimized during machining for super-ne surface [45].…”

Section: Tribology For Concave Surfacementioning

confidence: 93%

Surface modification of biomaterial embedded with pits using die sinker machine

Razak

Syahrullail²,

Nuraliza

et al. 2017

Scientia Iranica

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Abstract. Surface modi cation has been applied in many ways to enhance exclusive implant product. Electrical Discharge Machine Die Sinker (EDM DS) is a new approach to machine a macro surface on the biomaterial. In this study, investigations of current properties of EDM DS to obtain a new surface in titanium alloy (Ti-6Al-4V) and stainless steel (E-316-L), which placed pit on the material-sized (25 mm) diameter sample with a radius of 6.3 mm, were conducted. All the samples of concave textured circular pits with a xed diameter and depth of 0.5 mm were successfully machined. This study revealed that the pits were produced in the concave cup and the lubricant was con ned inside the pits, making easier contact between metal ball and metal concave surface. The results also show that the discharge machine is an attractive machining method for surface modi cation of biomaterial. This paper suggests that concave implant surface embedded with pits will work as a trap for lubricant and wear debris; in addition, it is possible to increase the lifespan of implant structure.

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Compound machining of titanium alloy by super high speed EDM milling and arc machining

Cited by 121 publications

References 23 publications

Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining

Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining

Study on blasting erosion arc machining of Ti–6Al–4V alloy

Surface modification of biomaterial embedded with pits using die sinker machine

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