Electric Hot Milling And Its Process Monitoring

With the rapid development of modern industrial technology, a lot of high strength, high hardness and high temperature resistant materials have been introduced, which caused some problems, such as large cutting force, high cutting temperature, serious tool wear and poor processing surface quality. To machine these materials, many processing methods have been invented. Electric Hot Machining has been regarded as an effective method against these materials. We have known that all the hot machining methods just been used in continuous cutting, such as turning or drilling. It can’t been used in milling that would spark to harm the workpiece. So a new electric hot machining is proposed in this paper and use it in milling.The paper has proposed the theory and experimental device. Then two typical difficult-to-machining materials which are hardness of T10A carbon tool steel and superalloy GH2132have been tested by the device. The efficiency of the new electric hot milling method has been proved by experiment and analyzing the surface roughness and the vibration signal that be processed by wavelet transform. The results show that the vibration amplitude has been reduced about5times and the surface roughness reduced about10times under a reasonable condition with the electric hot machining. And the microstructure of superalloy GH2132has never been changed. It has been proved by experiment on these method that it really can significantly reduce vibration and tool life in milling process. And it also can reduce surface roughness of the material. Besides, the device is not only cheap but also simple and practical.Besides, a new high-temperature hardness measurement method which based on electric hot technology is proposed. The change of hardness at high temperature of the two materials has been analyzed. The hardness of T10A carbon tool steel which has been hardened is nearly57HRC at room temperature. But the hardness drastically reduce to30HRC, when the material is heated to300℃. And superalloy GH2132which has been hardened is nearly53HRA at room temperature. The hardness reduce to46HRA, when the material is heated to600℃-700℃. The efficiency of the new high-temperature hardness measurement method has been proved by the experiments. So the efficiency of the new electric hot milling method has also been proved.