EDM Superalloy Electrolytic Composite Machining Equipment And Application

Electrical processing technology has widely application in the current manufacturing industry, and it plays an important role in especially in shaping machining of materials that is difficult to machining. EDM and ECM is the main form of EDM technology. EDM is suitable for cutting hard metal materials and machining special parts with complicated surface shapes. But the EDM will generate a recasting layer on the surface of the parts. Normally, there can be micro crafts inside the recasting layers. The micro crack is easy to spread under the alternating loading, and fracture of the part will be caused. Electrochemical machining is the processing working on the electrochemical dissolution principle. It has the advantages such as high efficiency, non-wearing tool, good machined surface quality, no recasting layer and no mechanical cutting force. But the electrolytic process cannot reach a high accuracy. The process finishes first electrical discharge machining (EDM) and then electrochemical machining to remove the recasting layer caused by the former electrical discharging machining, in order to satisfy the high requirements of precision and surface quality of parts using the one tool electrode and processing station.High-temperature alloy is a kind of material that is difficult to machining, which is widely used in aerospace and other fields. The machining of special-shaped hole generally use EDM machining, which is easy to form a recast layer on the machined surface. Here we use the compound of EDM - electrochemical machining to manufacture the special-shaped hole of High-temperature alloy.(1) Designing and building up electric discharge and electrolysis combining experiment platform fixing the main spindle of the EDM drilling machine on the Z axis of the three axis NC machine tool. Design a clamping tool, an electrolytic bath and an electrolyte circulating system. Use high temperature hard alloy with 3mm in thickness as the workpiece material.(2) The effect of various process parameters on the quality of complex processing was studied. The pre-experiment was explored with a brass electrode of a diameter of 2mm. Verifying that the current density, processing time, frequency, duty cycle and other parameters of the electrolytic polishing process, analyzing the high frequency narrow pulse current electrolysis process parameters at different current circumstances recast layer removal effect of impact, give the most reasonable electrolytic machining current parameters to remove EDM produced into a recast layer.(3) with the most reasonable electrochemical machining current parameters to remove the recasting layer caused by EDM process, obtaining high surface quality of the hole without recast layer on high temperature alloy GH4169. Then compare the application range of the electro - sparking electrolysis combined process and provide more practical machining method to different technical requirement.