Modeling of flow and debris ejection in blasting erosion arc machining in end milling mode
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Modeling of flow and debris ejection in blasting erosion arc machining in end milling mode Ji-Peng Chen1,2 • Lin Gu3
•
Wan-Sheng Zhao3 • Mario Guagliano2
Received: 15 April 2020 / Revised: 9 September 2020 / Accepted: 21 October 2020 / Published online: 20 November 2020 Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract Blasting erosion arc machining (BEAM) is a typical arc discharge machining technology that was developed around 2012 to improve the machinability of difficult-to-cut materials. End milling BEAM has been successfully developed and preliminarily applied in industry. However, owing to the high complexity of the flow field and the difficulty of observing debris in the discharge gap, studies of the flow and debris in end milling BEAM are limited. In this study, fluid dynamics simulations and particle tracking are used to investigate the flow characteristics and debris ejection processes in end milling BEAM. Firstly, the end milling BEAM mode is introduced. Then the numerical modeling parameters, geometric models, and simulation methods are presented in detail. Next, the flow distribution and debris ejection are described, analyzed, and discussed. The velocity and pressure distributions of the axial feed and radial feed are observed; the rotation speed and milling depth are found to have almost no effect on the flow velocity magnitude. Further, debris is ejected more rapidly in the radial feed than in the axial feed. The particle kinetic energy tends to increase with increasing milling depth, and smaller particles are more easily expelled from the flushing gap. This study & Lin Gu [email protected] 1
School of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, People’s Republic of China
2
Department of Mechanical Engineering, Polytechnic University of Milan, Piazza Leonardo da Vinci, 32, Milan, Italy
3
State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, People’s Republic of China
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attempts to reveal the flow field properties and debris ejection mechanism of end milling BEAM, which will be helpful in gaining a better understanding of BEAM. Keywords Modeling Flow Debris ejection Blasting erosion arc machining (BEAM) End milling
1 Introduction Electrical discharge machining (EDM) is an unconventional machining method that has been widely used in industry for many years. In EDM, the discharge gap between the anode and cathode is filled with a liquid dielectric, which initially acts as an insulator. The dielectric then breaks down under an electric field and forms a high-temperature plasma channel, resulting in material removal by melting and evaporation [1]. Spark discharge is the main type of discharge in EDM. It has a lower energy density than arc discharge and is generally regarded as a transitional stage in arc discharge in terms of the ultraviolet intensity, frequency, pulse width, pulse energy, current, temperature, and so o
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