TC4钛合金短电弧钻孔工艺性能研究

Research on the performance of short electric arc drilling process of TC4 titanium alloy

为了提高小孔钻削的加工效率和尺寸精度,文章提出了一种新颖高效的管电极短电弧钻孔方法。然而,由于电弧放电能量过大与进给速度不匹配,使得高效、高尺寸精度的小孔加工困难重重。文章揭示了基于脉冲电源的短电弧钻孔的工作原理,分析了SEAD的电压电流波形和截面形貌。此外,还研究了不同电极极性、电压、脉冲频率、占空比和电极进给速率对材料去除率(MRR)、电极相对磨损比(REWR)、平均直径和锥度的影响。最后,通过工艺参数优化实验,得到了小孔SEAD参数的最优组合,验证了小孔SEAD的加工性能。实验结果表明,在最佳加工参数下,小孔SEAD的材料去除率最高,为84.51μm/s,电极相对磨损比较低,为29.34%。加工小孔的最小平均直径和锥度分别为698.49μm和0.001 1°。

To improve the machining efficiency and dimensional accuracy of small hole drilling,a novel and efficient method of small hole short electric arc drilling(SEAD)by tube electrode is proposed.However,due to the mismatch between excessive arc discharge energy and feed rate,efficient and high dimensional accuracy small hole machining is fraught with difficulties.This paper reveals the mechanism of SEAD based on pulsed power supply,and analyzes the voltage-current waveform and cross-section topography of SEAD.In addition,the influence of different electrode polarity,voltage,pulse frequency,duty cycle,and electrode feed rate on material removal rate(MRR),relative electrode wear ratio(REWR),average diameter,and taper were investigated.Finally,an optimum combination of small hole SEAD parameters was obtained through a process parameter optimization experiment,which confirmed the machining performance of small hole SEAD.The experimental results show that under the optimal machining parameters,small hole SEAD achieves the highest MRR of 84.51μm/s and a relatively low REWR of 29.34%.The minimum average diameter and taper of the machined small hole were 698.49μm and 0.0011°,respectively.