基于田口法的TC4钛合金电化学车削试验研究

Experimental study on electrochemical turning of TC4 titanium alloy based on Taguchi method

通过对电化学车削加工(Electrochemical Turning,ECT)原理及其相关的工艺参数的研究,分析了快速转动的工件对保持工作间隙流场稳定的影响因素。并基于可实现无级调速的高速电机搭建试验平台,用单一因素试验分析了电化学车削TC4钛合金的各工艺参数对工件的材料去除率和表面粗糙度的影响。选取L_(16)(4^(4))正交表进行正交试验,基于田口方法进行分析,研究了电解液浓度、加工电压、工具直径和工件转速对工件材料去除率和表面粗糙度Ra的影响规律。经主效应分析,各加工参数对材料去除率影响因素大小依次为加工电压>工具直径>电解液浓度>工件转速。以材料去除率最大为目标的最佳工艺参数组合为加工电压20 V,电解液浓度250 g/L,工具直径2.0 mm,工件转速800 r/min。各加工参数对表面粗糙度影响因素大小依次为电解液浓度>工件转速>工具直径>加工电压。以表面粗糙度最小为目标的最佳工艺参数组合为加工电压15 V,电解液浓度200 g/L,工具直径1.0 mm,工件转速800 r/min。以材料去除率尽可能大、表面粗糙度尽可能小为目标,得到最佳工艺参数组合为加工电压20 V,电解液浓度250 g/L,工具直径2.0 mm,工件转速800 r/min。在该工艺参数组合下进行试验,材料去除率为0.0814 g/min,工件表面粗糙度Ra值为2.014μm,优于正交试验中的相对最优设计,即材料去除率0.0766 g/min,表面粗糙度Ra值2.158μm。

Based on the research of electrochemical turning machining principle and related process parameters,the process peremeters of fast rotating anode workpiece on maintaining the stability of working gap flow field were analyzed.Based on the experimental platform of high speed motor which can realize stepless speed regulation,the influence of various process parameters of electrochemical turning TC4 titanium alloy on material removal rate and surface roughness of the workpiece was analyzed by single factor experiment.L_(16)(4^(4))orthogonal table was selected for orthogonal experiment.Taguchi method was used to analyze the effects of electrolyte concentration,processing voltage,tool diameter and workpiece rotation speed on material removal rate and surface roughness Ra.According to the main effect analysis,the order of influencing factors of each machining parameter on material removal rate is machining voltage>tool diameter>electrolyte concentration>workpiece rotation speed.The optimal process parameter combination with the maximum material removal rate is processing voltage 20 V,electrolyte concentration 250 g/L,tool diameter 2.0 mm and workpiece rotation speed 800 r/min.The order of process peremeters of each machining parameter on the surface roughness is electrolyte concentration>workpiece rotational speed>tool diameter>machining voltage.The optimal combination of process parameters with minimum surface roughness is machining voltage 15 V,electrolyte concentration 200 g/L,tool diameter 1.0 mm,workpiece rotation speed 800 r/min.Aiming at material removal rate as large as possible and surface roughness as small as possible,the optimal combination of process parameters is machining voltage 20 V,electrolyte concentration 250 g/L,tool diameter 2.0 mm and workpiece rotation speed 800 r/min.Under the combination of process parameters,the workpiece with material removal rate of 0.0814 g/min and surface roughness Ra value of 2.014μm is fabricated,which is better than the relative optimal design in the orthogonal table with material removal rate of 0.0766 g/min and surface roughness Ra value of 2.158μm.