Flow Field Simulation And Process Research Of Edm Milling On Titanium Alloys

For its excellent material performance,titanium alloys has been widely used in the fields such as aerospace,petrochemical industry,automotive engineering,and the medical engineering etc.However, there were the problems of tools wear quickly and high processing cost with traditional machining method.And there was the problem of low efficiency with EDM.This paper studied the technology of EDM milling titanium alloys,reduced the manufacturing cost of titanium alloy materials and achieved the goals of high efficiency and low wear in machining titanium alloys,which had the great significance to the production and processing of titanium alloys.This paper studied the machining mechanism and machining process of EDM milling titanium alloys.The vital processing conditions such as the properties of work-piece materials,polarity effect,characteristics of working medium,electrode rotation,and dielectric flushing condition were analyzed theoretically respectively.And this paper set up the flow field model of EDM milling titanium alloys,and the internal flow field was calculated by using the simulation software FLUENT.In order to know about the discipline of gap flow field,dielectric flushing pressure,electrode speed,milling depth and the properties of work-piece materials were analyzed.This paper had designed a single factor experiment to verify the conclusions which were obtained by flow field simulation.And the electrical parameters which had a significant impact on processing effect were analyzed through experiments.The response surface experiment was designed with central composite experiment design method.The variables such as pulse width,pulse interval,peak current,liquid pressure and their interaction which had a significant impact on the processing effect was analyzed,and the optimal combination of process parameters was obtained.The main components of discharge debris were analyzed,the alloy sample was made from discharge debris and aluminum by powder’s alloying technique in certain ratio.the alloy sample’ performance had been tested,the results showed that the mechanical properties of aluminum had been improved after doping.Through improving the process conditions of EDM milling titanium alloys and optimizing its process parameters, the goals of high efficiency and low wear in machining titanium alloys was achieved.Compared with conventional milling, the material removal rate(MRR) was improved and the tool wear rate(TWR) was reduced.the best MRR was over 23cm3/min,while the TWR can reach 0.089%. In addition,this paper has studied the recycle of discharge debris on titanium alloys.