Abstract
In this study, the machining characteristics of pulse short arc milling (SEAM) Ti6Al4V alloy were studied. In this regard, the influence of SEAM parameters on the material removal rate (MRR), relative electrode wear ratio (REWR), and surface integrity of Ti6Al4V is studied. A wide variety of processing parameters, including different voltages, frequencies, duty cycles, flushing pressures, electrode rotation speeds, and electrode feed rates, are considered in the investigation. Scanning electron microscope (SEM), energy dispersive spectrograph (EDS), and micro-hardness analysis are applied to analyze results. Moreover, a multichannel data acquisition system is used to measure gap voltage and gap current. Obtained results cover the variation of MRR, REWR, surface roughness (Ra), average resolidified layer thickness, and average heat-affected zone thickness with different processing parameters. Furthermore, the electrode surface morphology and chemical composition of the negative growth of REWR are studied. Based on the obtained results, the microstructure of the resolidified layer and heat-affected zone of the workpiece cross-section is confirmed. This study provides a basis for the high-quality pulse SEAM technology of difficult-to-machine (DTM) materials to enter the semi-finishing field.
Highlights
Studies show that titanium alloys have excellent physical and mechanical properties so that they are widely applied in diverse applications, including aerospace, marine and biomedical fields
This study provides a technological basis for the high-quality pulse short electric arc milling (SEAM) technology of difficult-to-machine (DTM) materials to enter the semi-finishing field
The abovementioned methods improved the performance of electrical discharge machining (EDM) processing to a certain extent, the improvement of the processing efficiency is still limited
Summary
Studies show that titanium alloys have excellent physical and mechanical properties so that they are widely applied in diverse applications, including aerospace, marine and biomedical fields. Liu et al studied the performance of SEAM in machining Ti6Al4V based on the DC power supply They found that the maximum MRR of Ti6Al4V reaches 15100 mm3/min, and the surface roughness SZ reaches 699.92 μm [19]. It is of significant importance to consider the influence of voltage, frequency, duty cycle, flushing pressure, electrode rotation speed and feed rate on the MRR, REWR and surface integrity of pulsed SEAM machining Ti6Al4V. In this regard, some experiments will be carried out. It is expected to lay the foundation for the realization of the pulse SEAM Ti6Al4V process entering the semi-finishing stage
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