Obtaining high surface quality in electrolyte jet machining TB6 titanium alloy via enhanced product transport

2020 ◽  
Vol 276 ◽  
pp. 116381 ◽  
Author(s):  
Yang Liu ◽  
Ningsong Qu
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
High Surface ◽  
High Surface Quality ◽  
Tb6 Titanium Alloy ◽  
Electrolyte Jet

Experimental Study of Pulsed Electrolyte Jet Machining for Small Hole

2010 ◽  
Vol 458 ◽  
pp. 307-312 ◽  
Author(s):  
Yi Quan Yu ◽  
Jian She Zhao ◽  
Bing Hui Li ◽  
Jia Wen Xu
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Pulse Power ◽  
Small Hole ◽  
High Surface Quality ◽  
Good Surface ◽  
Dc Power ◽  
Hole Making ◽  
Main Effects ◽  
Electrolyte Jet

For the difficulties of machining small hole on difficult-to-cut materials, a study of hole-making technology by pulsed electrolyte jet machining is carried out. Main effects of DC power and pulse power on the hole conicity, surface quality and drilling efficiency are studied in this paper. The experiment results show that: hole with high surface quality can be available and the hole conicity is effectively reduced by using pulsed electrolyte jet machining; DC is suitable for improving efficiency when the ECM voltage is less than 300V, while pulse power supply shall be adopted to achieve good surface quality and high drilling efficiency when the ECM voltage is more than 300V.

scholarly journals Effects of Electrolyte Flushing and Surface State on Electropolishing TB2 Titanium Alloy

2021 ◽  
Author(s):  
Ying Wei ◽  
Xiaolong Fang ◽  
Ningsong Qu ◽  
Di Zhu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Quality ◽  
Flow Rate ◽  
High Surface ◽  
Processing Parameters ◽  
Process Time ◽  
High Surface Quality ◽  
Metal Plates ◽  
The Ideal

Abstract TB2 titanium alloys are widely used in the aerospace industry. A high surface quality is required for the performance and fatigue life of titanium alloy parts. Electropolishing is useful for thin metal plates owing to its good processability and conformability. In this study, electrolyte flushing was proposed for electropolishing a large surface and a NaCl-containing ethylene glycol electrolyte was adopted. Three different mechanical grindings were employed for pretreatment, and the ideal surface quality was obtained with a rubber grinding head. Therefore, in the process of electropolishing a large surface, electrolyte flushing is superior to stirring because its flow field is even and controllable. The effects of the main processing parameters (voltage, flow rate, and process time) on the surface roughness and morphology were studied. Finally, a mirror-like surface with a surface roughness of 10.5 nm was obtained after flushing electropolishing for 30 min under a voltage of 25 V and a flow rate of 0.84 m/s.

scholarly journals Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

2021 ◽  
Author(s):  
Lukas Seeholzer ◽  
Stefan Süssmaier ◽  
Fabian Kneubühler ◽  
Konrad Wegener
Keyword(s):  
Surface Quality ◽  
Influencing Factors ◽  
Material Properties ◽  
High Surface ◽  
Workpiece Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Surface Temperatures ◽  
Process Forces ◽  
The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Variothermal Foam Injection Molding - Dimensional Stability with High Surface Quality

2017 ◽  
Vol 36 (3) ◽  
pp. 151-166 ◽  
Author(s):  
Christian Hopmann ◽  
Nicolai Lammert ◽  
Yuxiao Zhang
Keyword(s):  
Surface Quality ◽  
Surface Defects ◽  
Control Strategies ◽  
High Surface ◽  
Skin Layer ◽  
High Surface Quality ◽  
Major Disadvantage ◽  
Scope Of Application ◽  
Specific Material ◽  
Foam Injection Molding

Thermoplastic foam injection moulding offers various advantages for both processing and product design. Despite its many benefits, the moderate surface quality still constitutes a major disadvantage of this process. The mould temperature can be controlled dynamically to improve the surface quality. Different dynamic temperature control strategies are employed and analysed regarding their effectiveness and scope of application. Mould temperatures above the specific material transition temperatures allow the surface defects to be cured and enable the production of foamed thermoplastic parts with surface qualities comparable to those of the compact reference samples. The high mould temperatures during the injection phase alter the foam structure and the skin layer thicknesses, which impacts the mechanical properties.

scholarly journals Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Machines ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 325
Author(s):  
Muslim Mahardika ◽  
Martin Andre Setyawan ◽  
Tutik Sriani ◽  
Norihisa Miki ◽  
Gunawan Setia Prihandana
Keyword(s):  
Taguchi Method ◽  
Surface Quality ◽  
Process Parameters ◽  
Applied Voltage ◽  
High Surface ◽  
Machining Process ◽  
Machining Parameters ◽  
Pareto Analysis ◽  
High Surface Quality

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

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

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.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

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