TC4 Titanium Alloy Ultrasonic Mixed Powder Electric Spark Machining Device Design And Experimental Research

Due to its low density,corrosion resistance,high strength and good weldability and toughness,TC4 titanium alloy has been widely used in aerospace and medical equipment where high precision is required.EDM is used as a special processing method.Continuous pulse discharge converts electrical energy into thermal energy for the purpose of removing surface material.In the conventional EDM,there are problems of low processing efficiency,poor processing quality,and polishing,grinding,etc.after processing.The appearance of mixed powder sparks provides a solution to the above problems to some extent.In order to further improve the difficulties encountered in the processing of TC4 titanium alloy,this paper proposes an ultrasonic mixed powder electric spark composite machining,and attaches the ultrasonic device to the workpiece to explore the positive effect of ultrasonic in the powder electric discharge machining.Based on the EDM CNC machine tool,a set of ultrasonic mixed powder EDM machining device that can realize the horizontal vibration of the workpiece is designed.Based on ANSYS modal analysis,an ultrasonic vibration platform capable of carrying vibrations of workpieces with different shapes and sizes was designed.FLUENT software was used to simulate the flow field distribution of different bottom height,impeller speed and impeller shape,and related installation and debugging were carried out.check.Secondly,a series of ultrasonic welding powder electric spark machining processing experiments were carried out.First,while maintaining the electrical parameters unchanged,the effects of processing depth,aluminum powder concentration,and processing area in the processing of TC4 titanium alloy were tested.Then,under the same process conditions,9 setsof processing comparison tests were performed on ordinary electric spark and ultrasonic electric spark,mixed powder electric spark and ultrasonic mixed powder electric spark.The analysis found that adding mixed powder is better than unmixed powder processing,and additional ultrasound can improve the processing effect,and the effect of mixing powder is greater than that of additional ultrasound.Then the four-factor four-level orthogonal experiment is designed,and the two methods of range analysis and signal-to-noise ratio analysis are used respectively to explore the influence of electrical parameters on the processing effect,and the combination of signal-to-noise ratio and gray correlation degree will be used.The multi-objective optimization problem is transformed into a single-objective gray correlation degree problem,and the optimal parameter set is obtained through verification experiments.Finally,with the designed ultrasonic hybrid electric spark orthogonal test as the data sample,the MATLAB software is used to program the process,and the ultrasonic vibration mixing powder electric spark machining is applied to the workpiece to predict the BP network model,and the predicted value and the experimental value are adopted.The comparison proves that the established model can accurately predict the surface roughness and processing rate under the relevant test parameters after training,and has certain learning and generalization ability.