Discharge characteristics of W-Cu electrode in short electrical arc discharge machining of Inconel 718
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ORIGINAL ARTICLE
Discharge characteristics of W-Cu electrode in short electrical arc discharge machining of Inconel 718 XueZhi Li 1 & JianPing Zhou 1 & Yan Zhang 1 & DaQian Sun 2 & HongMei Li 2 Received: 22 November 2019 / Accepted: 1 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The current application of short electrical arc discharge machining (SEAM) for cemented carbide removal is limited by its surface quality. In this study, tungsten-copper (W-Cu) alloy materials with different proportions as electrodes were studied by experimental methods. The mechanism of electrical parameters and composition content affecting the processing performance of SEAM was investigated, including surface roughness (Ra), material removal rate (MRR), micro-morphology, and the recast layer thickness (RLT). The results showed that the maximum MRR with W50-Cu electrode was 41 g/min, and the processing performance was the best with W90-Cu electrode in the U of 25 V, F of 2.3 KHz, and D of 55%. The W90-Cu electrode could provide good processing, and a thinner and more uniform recast layer was found on the workpiece surface. Therefore, W-Cu alloy tools are recommended when the hard surface materials machined by SEAM requires higher accuracy and surface finish. Keywords Short electrical arc milling . W-Cu . Surface roughness . Material removal rate . The recast layer thickness . Processing characteristics
1 Introduction Short electrical arc machining (SEAM) is a new type of highefficiency processing technology, belonging to the field of electrical processing technology in the special processing industry. It is an electro-processing method for removing conductive materials by utilizing short arc groups or spark groups generated between two electrodes under the action of a certain proportion of gas-liquid mixed working medium [1]. Compared with the electrical discharge machining (EDM), the pulse width, pulse current, single pulse energy, and average energy of short arc are much larger than that of spark [2, 3]. Thus, SEAM has a high material removal rate (MRR), and the unilateral cutting depth can reach more than 15 mm, which provides an efficient and feasible means for the processing of super-hard alloy parts such as cement rolls, aero engine core * Yan Zhang [email protected] 1
School of Mechanical Engineering, Xinjiang University, Ürümqi 830000, China
2
Key Laboratory of Automobile Materials, School of Materials Science and Engineering, Jilin University, Changchun 130022, China
unit casing, integral impellers, and honeycomb seals. It is widely used in agricultural equipment, petrochemical, hydropower, aerospace, and other industries [4–6]. However, due to the narrowness of the short arc discharge channel, it is not possible to effectively stabilize the arc combustion and the protection of the tool electrode, and it is difficult to ensure good surface quality [7]. Therefore, a reasonable choice of tool electrode materials is necessary to improve the stability and processing quality and reduce
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