Research On Powder-mixed Electrochemical Discharge Machining Process

With the new materials constantly appearance, more and more nonmetallic and non-conductivematerials are applied in aerospace and medical equipment.But the machining method of the nonmetallic and non-conductive is a big problem. In this paper,a new machining method based on electrochemical discharge machining (ECDM) has beeninvestigated, which putting conductive powder into the ECDM electrolyte to process non-conductivematerials.Experiments of Pyrex glass of powder-mixed ECDM (PM-ECDM) have been conducted. Theinfluence parameters such as applied voltage, electrolyte concentration and powder concentration areanalyzed, and some milling experiments with the best machining parameters are conducted. The maincontents are as follows:(1) The principles and characteristics of PM-ECDM are introduced, and two machining modelsare established. The role of conductive particles which improving the surface quality in the machiningprocess based on machining models are analyzed.(2) Experimental platform is designed for the experiments, and motion path of the platform isprecisely controlled by control system. Fixture, electrolyte mixing system and feed system of Z axisare designed and made.(3) Drilling experiments are designed with different machining voltage, electrolyte concentrationand powder concentration. To do some PM-ECDM milling experiments, the best process parametersare found out by analyzing the drilling results.(4) The principles and characteristics of PM-ECDM milling are introduced. Some millingexperiments are conducted with the best parameters and the path of tool electrode reasonablyplanning.