Mechanism And Experiment Studies Of TC4on Controllable Burned Grinding Induced By Electrical Discharge Machining

Titanium alloy is a kind of difficult-to-cut material, there are high grinding force, high grindingtemperature, and wheel wear etc problems in grinding. Electrical discharge machining (EDM) couldmachine materials no matter their rigidity and intensity, so it is suitable to machine difficult-to-cutmaterials. However, maching area of EDM is concentrated in a small range around discharge channel,and the heat transferred to workpiece is limited, so EDM is limited in producing. The paper proposesa controllable burned grinding technology induced by EDM, the main research contents are:(1) Construct testing system. Design slotted conductive wheel, pulse generator, driving device,electricity-supply equipment, insulating device, and gas-supply equipment, construct burned grindingtest system, meet machining needs.(2) Research on burned grinding mechanism. Analyze machining mechanism by materialremoval rate, surface quality, spindle motor power change etc. Use SEM to analyze surfacemorphology, find that the burned grinding surface is temper, no cracks, the Ra is0.59μm, similar tothe Ra of mechanical grinding, and while the Ra of EDM is1.29μm. Measure the spindle motorpower changes, find burned grinding is the least, that is95.2%and96.8%reduction of EDM grindingand mechanical grinding respectively.(3) Temperature field simulate. Use FEM to simulate burned grinding temperature field, and gettemperature field distribution. The result shows that, under specified parameters, burned grindingcould generate a soften layer of74μm depth. Verify the analysis result by testing, find the testingresult of soften layer depth is68μm, similar to simulating result.(4) Test research on soften layer. Research effect regularities of parameters to soften layer, suchas pulse width, pulse interval, voltage, wheel rotating speed, feed rate, pressure etc. The result showsthat, with pulse width, pulse interval, voltage, wheel rotating speed and pressure increasing, the softenlayer increases first and then reduces, and with feed rate increasing, the soften layer reduces. Providetheory basis to choose machining parameters reasonably and improve grinding performance oftitanium alloy.