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

Li, Jie; Li, Hansong; Hu, Xiaoyun; Niu, Shen; Xu, Guoliang

doi:10.3390/app10061941

Cited by 11 publications

(7 citation statements)

References 23 publications

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“…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.…”

Section: Analysis Of Simulation Resultsmentioning

confidence: 99%

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

et al. 2021

Applied Sciences

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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.

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Section: Analysis Of Simulation Resultsmentioning

confidence: 99%

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

et al. 2021

Applied Sciences

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“…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.…”

Section: Introductionmentioning

confidence: 99%

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

Wang

et al. 2022

Materials

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Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.

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“…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 .…”

Section: Introductionmentioning

confidence: 99%

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

Feng

et al. 2022

Sci Rep

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Electrochemical grinding (ECG) is processed by the combination of dissolution and grinding. It is very suitable for the processing of difficult-to-cut stainless steel, but its processing performance is restricted by the matching effect of dissolution and grinding. In this work, the processing of the torus surfaces of the stainless steel shaver cap was taken as the research object. A flow field model including the through-hole structure and the rotation of the grinding head was proposed to optimize the flow field distribution and promote the uniform dissolution of materials. The flow field simulation results showed that the rotational flow formed by the high-speed rotation prolonged the electrolyte flow path and was not conducive to the discharge of electrolytic products, and the reasonable selection of the diameter and distribution of the through-hole could reduce the velocity difference. The effects of rotational speed, feed rate, and inlet pressure on the flatness and surface roughness of the torus surfaces were experimentally investigated, and a better matching effect of dissolution and grinding was obtained. Moreover, the experimental results showed that the inner-jet ECG had a good prospect in the batch processing of high-hardness stainless steel parts.

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

Cited by 11 publications

References 23 publications

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

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

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

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

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