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Study of the Mechanism and Material Erosion Model of Near-Dry Electrical Discharge Milling

Author: XueRong
Tutor: GuLin
School: Shanghai Jiaotong University
Course: Aviation Aerospace Manufacturing Engineering
Keywords: Near-dry ED-milling crater radius material erosion model energy distribution ratio
CLC: TG661
Type: Master's thesis
Year: 2012
Downloads: 63
Quote: 1
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Abstract


Near-dry electrical discharge milling is a new EDM process by using the gas-liquid two phase flow as its dielectric working medium instead of oil based working fluid. Compared with the traditional EDM, it not only produces less waste, low cost, but also can achieve higher material removal rate and lower tool wear ratio.In order to have a further understanding of the near-dry ED-milling mechanism, this thesis investigates the machining process and presents a novel method to study the ratio of the energy distributed into electrodes. Based on a series experiments by using Cr12 steel, titanium alloys as workpiece and copper, graphite as tool electrode, the thermo-fluid coupling physical model for describing the crater formation and the key factor of energy distribution ratio into electrodes were identified.The crater radius was measured by experiments under different machining conditions, and the relationship between the crater radius and the pulse durations as well as the discharge currents was deducted by using the least squares method. The ratio of energy distributed into the electrodes was identified by comparing the simulation results and the experimental results based on the established thermo-fluid coupling model. Furthermore, the reliability of this model was verified by comparing the crater dimensions achieved by measurement and calculation.The experimental results and the analysis show that in near-dry ED-milling, the ratio of energy distributed into the anode is much larger than that into the cathode. Besides, the positive workpiece polarity is preferred for a higher material removal rate. The material removal rate and surface roughness could be predicted by a proper material erosion model. It’s also useful for the optimization of the processing parameters and reduction of the cost in near-dry electrical discharge milling.

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CLC: > Industrial Technology > Metallurgy and Metal Craft > Metal cutting and machine tools > Special machine tools and processing > Electric machines and their processing
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