Fundamental Investigation of Ultrasonic Assisted Pulsed Electrochemical Grinding of Ti-6Al-4V

Abstract

Aiming at the development of a novel grinding technology for the highly efficient machining of difficult to machine materials such as Ti-6Al-4V, an ultrasonic assisted pulsed electrochemical grinding (UAECG) method was proposed. The current work is to reveal the fundamental grinding characteristics of the UAECG of Ti-6Al-4V by experimentally investigating the effect of vibration amplitude on grinding forces, actual material removal and work-surface roughness under different process parameters such as the input voltage and rotational speed. Summarizing the obtained results revealed that the grinding forces in UAECG are significantly smaller than those in conventional grinding (CG).

Structural Design of a Special Machine Tool for Internal Cylindrical Ultrasonic-Assisted Electrochemical Grinding

“…According to their structural features and machining modes, machine tools are classified into vertical and horizontal. In previous research on UAECG [ 5 , 7 , 8 , 9 , 18 ], very small lightweight conductive grinding wheels and integrated ultrasonic electric spindles were used; the conductive grinding wheel on-machine dressing was not considered, and all machine tools were all vertical structures. For the ICUAECG, a large conductive grinding wheel and ordinary grinding electric spindle are used, the ultrasonic vibration system needs to be installed, the volume and weight of the grinding electric spindle and conductive grinding wheel are large, and considering the conductive grinding wheel on-machine dressing, the horizontal structure is appropriate for the special machine tool.…”

“…For UAECG, Wu et al [ 5 , 7 , 18 ] developed an ultrasonic-assisted electrochemical mill-grinding vertical machine tool by installing an ultrasonic electric spindle on a 3-axis NC machine tool. They studied the planar ultrasonic-assisted electrochemical mill-grinding of Ti-6Al-4V with a metal-bonded CBN grinding wheel of 1.8 mm in diameter.…”

Effects of processing parameters on the surface quality of wrought Ni-based superalloy by ultrasonic-assisted electrochemical grinding

“…S.S. Li, et al was conducted to compare and analyze the difference in cutting force of workpieces between UAECG technology and ultrasonic-assisted pulse electrochemical grinding processing technology. The results showed that the normal stress and tangential stress of ultrasonicassisted electrochemical grinding are respectively reduced by about 57% and 56% in comparison with that of traditional grinding [20][21][22].…”

“…However, there existed many defects for traditional processing methods such as low processing efficiency, serious tool wear, high frictional heat and residual stress, which were hardly beneficial for the processing of difficult-to-machine materials. A series of new processing technologies were thus proposed such as laser processing, electric discharge processing, electrochemical processing and high-speed water jet processing [3][4][5]. Generally, nontraditional machining exhibits many advantages such as high machining efficiency and accuracy, low tool wear and low frictional heat [6，7].…”

Micro Electrochemical Milling of Micro Metal Parts with Rotating Ultrasonic Electrode

“…Li et al proposed an ultrasonic-assisted pulse electrochemical grinding method. The influence of vibration amplitude on grinding force, material removal rate and workpiece surface roughness under different machining parameters such as applied voltage and rotating speed was studied [ 30 ].…”