Optimisation And Experimental Study Of Short Electric Arc Milling Process Parameters For Aerospace Aluminium Alloys

The 7075 aluminium alloy has the advantages of light material and high specific strength,and is the material of choice in the aerospace field,so it is also called aviation aluminium alloy.These aluminium alloys have shown excellent performance in aerospace manufacturing,but they are still unavoidable in rough machining with large cutting margins and problems such as deformation and chip tumours,especially in aeroengine cases.Therefore,this paper aims to solve the problems of tool damage and workpiece deformation in aluminium alloy machining through the study of short electric arc milling process of aviation aluminium alloy,which has scientific significance and application value to improve the thrust-to-weight ratio of aircraft engines.This paper combines theory and experiment to compare the differences between the short electric arc milling process characteristics of aerospace aluminium alloys and nickel-based alloys.Analysis of the etching characteristics of materials with low melting points,softer materials and susceptibility to oxidation from the differences in etching products between aerospace aluminium alloys and nickel-based alloys.On the basis of this study,the process parameters of adjustable process parameters in short electric arc milling of aerospace aluminium alloys are studied on the process pattern and etching process of short electric arc milling of aerospace aluminium alloys.This paper uses the central composite experimental design method in response surface analysis to prepare process experiments.The effect of the interaction of factors under four factors and five levels of voltage,duty cycle,pulse frequency and punching fluid pressure on the machining effect is analysed.Finally,an efficient and low-loss combination of parameters for short electric arc milling of aerospace aluminium alloys is obtained.This paper analyses the change in workpiece properties after short electric arc milling of aerospace aluminium alloys and calculates the short arc milling allowance.The corresponding advantages of short electric arc milling,mechanical milling and electrolytic machining are compared to strengthen the process of machining aerospace aluminium alloys and prepare the process interface between short electric arc efficient milling and electrolytic compound machining.This paper explored and optimised the process parameters of short electric arc efficient milling of aerospace aluminium alloys to achieve efficient and low loss machining of aerospace aluminium alloy materials.Compared to conventional machining and electrolytic machining,the machining efficiency of the aerospace aluminium alloy is improved and the electrode loss of the tool is reduced,with a machining efficiency of 16733 mm3/min and a relative tool wear rate of 1.549% under optimum process conditions.In addition,this paper achieves a hybrid of short electric arc efficient milling and electrolytic machining.The surface strengthening of the aerospace aluminium alloy material has been carried out to ensure machining efficiency and quality for the aerospace application environment.