Abstract
This paper studied the rule of micro-hole in electrochemical jet machining (EJM) of TC4 alloy and established the mathematical model of machining process and predicted the machining profile. Considering the influence of machining gap and machining time, orthogonal experiment was designed. This paper established the mathematical model of the electrochemical jet machining process of TC4 alloy based on the response surface analysis (RSA) method. The results indicate that the electrochemical jet can improve the directivity of machining, reducing the machining gap can improve the machining efficiency, but the jet will cause secondary corrosion and abrupt change of current at the edge of inlet. The mathematical model based on response surface analysis is accurate after variance test. The experimental results show that the average error between the established prediction model of machining depth and the actual value is 2.32%, and the average error of the prediction model of inlet radius is 2.18%.
Highlights
Electrochemical Jet Machining (EJM) is a machining technology based on anodic dissolution
EJM can make the electric field distribution more concentrated compared with traditional electrochemical machining, it allows for more micro processing [1,2]
The anode tool has no loss, and the wear of tool material can be avoided compare with traditional cutting process, which is very suitable for the processing of difficult-machining metal materials such as titanium alloy
Summary
Electrochemical Jet Machining (EJM) is a machining technology based on anodic dissolution. Scholars have done much work on the corrosion characteristics, machining methods and finite element model establishment of materials in the EJM process [7,8,9,10], but for the specific machining process, the mathematical model between each parameter and machining profile is less studied. Munda et al used response surface analysis to model the electrochemical machining process of stainless steel [13]. All these works have proved that parametric modeling method has a very high value for the optimization of machining process. Established the mathematical model between the jet electrochemical machining parameters and the profile of micro-hole based on the response surface analysis method to realize the prediction of the micro-hole profile and provide guidance for the processing technology
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