Simulation And Experimental Investigation Of Electrochemical Mill-Grinding Of GH4169 Alloy

Electrochemical mill-grinding（ECMG）is a new method of compound machining by copying NC milling,in which a simple rodlike grinding wheel is used as the cathode and the high-speed rotating grinding wheel is formed to process the workpiece along a set trajectory.In ECMG the electrochemical mill and grinding both take effect and it is possible to remove large allowance from the workpiece under excellent machining flexibility.ECMG is a very potential processing method for high efficiency machining and complex surface molding on superalloy and other difficult cutting metal materials.In this paper,a series of simulation analysis and experimental investigation of ECMG of GH4169 alloy have been done.The specific research contents are as follows:（1）In order to meet the needs of high efficiency machining for inner-jet ECMG,four kinds of rodlike grinding wheels are designed（the diameter is 10.2mm）,the original machining system is reformed and the electrical devices and the electrolyte system are redesigned;（2）The electric field simulation of ECMG process and the flow field simulation of machining zone are carried out,the effects of different grinding wheel structure,processing voltage and electrolyte pressure on the processing results are compared and analyzed;（3）The maximum feed rates of four kinds of grinding wheels under different voltage and electrolyte pressure were measured,and the experiment of groove machining is made,in which the maximum feed rate of 2.3mm?min^-1 and the material removal rate of 25.883mg?s^-1 are reached under the cutting depth of 10mm.Then the machining accuracy and the surface quality of the grooves are compared and analyzed under different machining conditions;（4）The causes of machining defects on the bottom of grooves are analyzed,and the structure of the grinding wheel bottom is optimized and improved,which reduces the undercutting of the bottom of the groove,and its flatness is improved.The optimized grinding wheel is used to process a complex sample and a good machining result is obtained.