Combining PMEDM with the tool electrode sloshing to reduce recast layer of titanium alloy generated from EDM

The experiments of micro-hole ablation are conducted firstly on titanium alloy Ti-6Al-4V with Nd: YAG millisecond laser. A significant factor which affects the depth of blind hole is found: the depth of recast material. This paper closely examines the regularity of recast depth varying with laser parameters, discovering that the ratio of recast depth to the entire hole depth decreases as pulse width decreases, and increases as peak power decreases. Verification experiment is conducted on stainless steel 1Cr13, eventually micro-hole with very thin recast layer is drilled when the maximum peak power and the minimum pulse width of the present millisecond laser are used.

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Material Removal Rate in Electric Discharge Machining with Aluminum Tool Electrode for Ti-6Al-4V Titanium Alloy

Advances in Engineering Research and Application - Lecture Notes in Networks and Systems ◽

10.1007/978-3-030-64719-3_58 ◽

2020 ◽

pp. 527-533

Author(s):

Nguyen Huu Phan ◽

Vu Ngoc Pi ◽

Shailesh Shirguppikar ◽

M. S. Patil ◽

Mohsen Asghari Ilani ◽

...

Keyword(s):

Titanium Alloy ◽

Material Removal Rate ◽

Electric Discharge ◽

Material Removal ◽

Removal Rate ◽

Tool Electrode ◽

Electric Discharge Machining

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Experimental study on high-efficiency DC short electric arc milling of titanium alloy Ti6Al4V

10.21203/rs.3.rs-357272/v1 ◽

2021 ◽

Author(s):

Zongjie Zhou ◽

Kai Liu ◽

Yan Xu ◽

Jianping Zhou ◽

Lizhong Wang

Keyword(s):

Titanium Alloy ◽

Electrode Material ◽

Material Removal ◽

Electrode Materials ◽

Arc Discharge ◽

Specific Energy Consumption ◽

Base Material ◽

Electric Arc ◽

Tool Electrode ◽

Q235 Steel

Abstract Short electric arc milling (SEAM) is an efficient electrical discharge machining method, especially for the efficient removal of difficult-to-machine conductive materials with high hardness, high toughness, and wear resistance. In this study, titanium alloy Ti–6Al–4V is used as the research object to conduct machining experiments. The material removal mechanism of SEAM technology is studied using a DC power supply and different tool electrode materials (copper, graphite, Q235 steel, and titanium). The energy distribution of the discharge gap is analyzed using a data acquisition system and a high-speed camera. The arc is found to move with the spindle rotation in the process of arc discharge, and multi-point discharge occurs in the process of single-arc discharge. The voltage and current waveforms and the radius of the etched particles during the experiment were counted, the material removal rate (MRR) and relative tool wear rate (RTWR) are calculated, and the surface and cross-section micromorphology and hardness are analyzed. The experimental results show that when the electrode material is graphite, the maximum feed rate is 650 mm/min, the MRR can reach 17268 mm3/min, the ideal maximum MRR is more than 65000 mm3/min, and the RTWR is only 1.27%. When the electrode material is Q235 steel, the minimum surface roughness is 35.04 µm, and this material has good stability under different input voltages. When the electrode material is copper, the hardness of the resolidified layer is close to that of the base material, which is beneficial for further processing. The lowest specific energy consumption is 18.26 kJ/cm3 when titanium is used as the electrode material.

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Flow Field Simulation And Experimental Investigation On Macro Electrolyte Jet Electrochemical Turning of TB6 Titanium Alloy

10.21203/rs.3.rs-1012053/v1 ◽

2021 ◽

Author(s):

Yang Liu ◽

Ningsong Qu ◽

Zhi Qiu

Keyword(s):

Titanium Alloy ◽

Flow Field ◽

Contour Error ◽

Tool Electrode ◽

Machined Surface ◽

Tb6 Titanium Alloy ◽

Machined Surface Roughness ◽

Application Potential ◽

Electrochemical Turning ◽

Electrolyte Jet

Abstract Electrolyte jet electrochemical turning is an effective method to realize high-quality machining of titanium alloy rotating components; however, minimal research has been carried out in this field. This is because it is difficult to control the machining flow field, which leads to poor machining surface quality. In this work, numerical simulations were used to optimize the machining flow field and reduce the proportion of gas that mixed into the machining area. This can promote participation of the tool electrode tip in the electrochemical reaction and improve the machining efficiency. The effectiveness of the optimized machining flow field for jet electrochemical turning was verified experimentally. The results showed that all three kinds of revolving TB6 titanium alloy samples with different structures could maintain the original contour shape, with a contour error <1% and a machined surface roughness reaching Ra 2.414 μm. The results demonstrate the application potential of the jet electrochemical turning process.

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Optimization of Surface Roughness Parameters by Different Multi-Response Optimization Techniques During Electro-Discharge Machining of Titanium Alloy

Non-Conventional Machining in Modern Manufacturing Systems - Advances in Mechatronics and Mechanical Engineering ◽

10.4018/978-1-5225-6161-3.ch004 ◽

2019 ◽

pp. 82-108 ◽

Cited By ~ 2

Author(s):

Anshuman Kumar Sahu ◽

Siba Sankar Mahapatra

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Discharge Current ◽

Desirability Function ◽

Optimization Techniques ◽

Work Piece ◽

Tool Electrode ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Edm Process

In this chapter, the EDM process is performed by taking titanium alloy as work piece and AlSiMg prepared by selective laser sintering (SLS) process as tool electrode along with copper and graphite. The EDM is performed by varying different process parameters like voltage (V), discharge current (Ip), duty cycle (τ), and pulse-on-time (Ton). The surface roughness parameters like Ra, Rt, and Rz are measured by the use of surface roughness measurement machine. To reduce the number of experiments, design of experiment (DOE) approach like Taguchi's L27 orthogonal array has been used. The surface properties of the EDM specimen are optimized by desirability function approach, TOPSIS and VIKOR method, and the best parametric setting is reported for the EDM process. All the optimization techniques convergence to the same optimal parametric setting. The type of tool is the most significant parameter followed by discharge current and voltage. Better surface finish of EDM specimen is produced with lower level of parametric setting along with the use of AlSiMg RP electrode during EDM.

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Surfactant and graphite powder–assisted electrical discharge machining of titanium alloy

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415579019 ◽

2016 ◽

Vol 231 (4) ◽

pp. 641-657 ◽

Cited By ~ 21

Author(s):

Murahari Kolli ◽

Adepu Kumar

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Graphite Powder ◽

Recast Layer ◽

Dielectric Fluid ◽

Recast Layer Thickness

Surfactant and graphite powder–assisted electrical discharge machining was proposed and experiments were performed on titanium alloy in this investigation. Analysis was carried out to observe changes in dielectric fluid behaviour, material removal rate, surface roughness, recast layer thickness, surface topography and energy-dispersive X-ray spectroscopy. It was found out that the addition of surfactant to dielectric fluid (electrical discharge machining oil + graphite powder) improved the material removal rate and surface roughness. It was noticed to have reduced the recast layer thickness and agglomeration of graphite and sediment particles. Biface material migrations between the electrode and the workpiece surface were identified, and migration behaviour was powerfully inhibited by the mixing of surfactant. Surfactant added into dielectric fluid played an important role in the discharge gap, which increased the conductivity, and suspended debris particles in dielectric fluid reduced the abnormal discharge conditions of the machine and improved the overall machining efficiency.

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