Electrode-assisted hydrodynamic arc breaking for efficient side-cutting of Ti2AlNb

Abstract

This study introduces novel electrode-assisted hydrodynamic arc-breaking methods for the efficient side-cutting of Ti2AlNb, a material widely used in the aerospace industry but notorious for its machining difficulties. The research aims to overcome the limitations of traditional arc machining techniques, with a particular emphasis on deep-sidewall machining. The paper begins with an overview of electrode manufacturing processes used in electrode-assisted hydrodynamic arc-breaking methods. Following that, Fluent simulations are used to analyze particle behavior during the side-cutting process. The feasibility of these novel electrodes is then demonstrated using extensive single-factor experiments. The optimization of process parameters using orthogonal experiments, which significantly improves machining efficiency, is a crucial aspect of this study. The results showed that electrode-assisted arc breaking and hydrodynamic arc breaking for Ti2AlNb side-cutting processing increased the material removal rate by 65 % compared to conventional electrode materials, reduced relative electrode wear rate by 54 %, and reduced surface roughness by 85 %. Therefore, electrode-assisted hydrodynamic arc-breaking methods for side-cutting processing have a promising future in difficult-to-machine materials in the aerospace industry.