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Abstract
Electrochemical mill-grinding (ECMG) is an ideal technical means to achieve an efficient and precise machining of titanium alloy monolithic structural parts. In the rough ECMG process, the selection of a reasonable cutting depth can improve the machining efficiency of the rough machining. Adopting a reasonable cathode tool structure can achieve a higher precision in the formation of the rough surface, reduce the finishing allowance and tool wear of subsequent finishing. With this aim, the present research proposed a cathode tool with a reasonable structure. Simulation results showed that the designed cathode tool presented a good uniformity of the flow field in the machining gap, which resulted in a higher precision in the formation of the rough surface. For experimental validation, a larger cutting depth and a designed cathode tool was employed to carry out the rough and finish machining experiments on a Ti6Al4V titanium alloy. The experimental results show that a good flatness of the sidewall of the rough-machining groove was obtained by this scheme. Furthermore, the machining surface exhibited no flow marks, and rough machining accounted for 92.37% of total removal. Moreover, measurement of the micro-morphology, roughness and elemental composition of the machined surface, and the effects of different machining parameters on the surface quality of titanium alloys, were studied.
Highlights
Titanium alloy material is a structural material with a high temperature resistance, low density, high strength, and has a very important application value and broad application prospects in the fields of aerospace, electronic communication and marine engineering [1,2]
Even if the Analysis of the simulation results shows that the distribution of the flow velocity was directly cathode tool was rotated through different angles, the high-velocity area always acted in the middle related to the layout of the outlet slit
3, of which the material removal in the rough-machining stage accounted for 92.37%
Summary
Titanium alloy material is a structural material with a high temperature resistance, low density, high strength, and has a very important application value and broad application prospects in the fields of aerospace, electronic communication and marine engineering [1,2]. When ECMG adopts the method of spraying liquid on the side wall of the tubular tool, it can directly perform the “cut-in” processing with a large cutting depth from the side wall of the workpiece. It has significant advantages and broad application prospects in the field of efficient manufacturing of the structural parts of difficult-to-machine materials. A reasonable electrolyte outlet layout ensured the uniformity of the flow field in the machining gap; so as to obtain a better precision in the formation of the rough-machining surface and reduce the removal of the finishing and tool wear For this purpose, through the numerical simulation of the flow field, a scheme optimization study was.
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