Electrical arc contour cutting based on a compound arc breaking mechanism

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Electrical arc contour cutting based on a compound arc breaking mechanism

Guo-Jian He , Lin Gu , Ying-Mou Zhu , Ji-Peng Chen , Wan-Sheng Zhao , K. P. Rajurkar

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4) : 583 -595.

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Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4) : 583 -595. DOI: 10.1007/s40436-022-00406-0

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Electrical arc contour cutting based on a compound arc breaking mechanism

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¹ State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, 200240, Shanghai, People’s Republic of China

² School of Mechanical and Electronic Engineering, Nanjing Forestry University, 210037, Nanjing, People’s Republic of China

³ Center for Nontraditional Manufacturing Research, University of Nebraska-Lincoln, Lincoln, NE, USA

^b lgu@sjtu.edu.cn

Guo-Jian He is a Ph.D. candidate at the State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research interests include the technical and equipment of electrical arc machining (EAM) and micro electrical discharge machining (Micro-EDM).

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Lin Gu received his Ph.D. degree in Engineering from Harbin Institute of Technology. He is currently an associate professor in the State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research interests include advanced manufacturing technology for difficult-to-cut materials, such as EDM, arc discharge machining, and compound machining.

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Ying-Mou Zhu is a Ph.D. candidate at the State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, China. His research interests include EDM, WEDM and Blasting erosion arc machining (BEAM).

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Ji-Peng Chen received his Ph.D. degree from the State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, China. He is currently an assistant professor at School of Mechanical and Electronic Engineering, Nanjing Forestry University, China, and a visiting scholar at Polytechnic University of Milan, Italy. His research interests include advanced manufacturing technology.

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Wan-Sheng Zhao is a professor at Shanghai Jiao Tong University, Shanghai, China. He received his Ph.D. degree in Engineering from Harbin Institute of Technology. His research interests include advanced manufacturing technologies, such as electrical discharge machining, arc discharge machining.

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K. P. Rajurkar is a distinguished professor at University of Nebraska-Lincoln, Lincoln, USA. He received his Ph.D. degree from Michigan Technological University. His research interests include modeling and analysis of manufacturing processes, systems sensing and control of traditional and nontraditional macro, micro and nano manufacturing processes.

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Abstract

Electrical arc contour cutting (EACC) is a novel high-efficiency material cutting process that applies arc plasma to perform efficient and economical contour cutting of difficult-to-cut materials. Compared to conventional electrical arc machining (EAM), this process can remove the allowance of open structures and plates in bulk mode, rather than entirely in the form of debris. Compared with existing contour cutting methods, EACC possesses the advantages of high cutting efficiency and a deep cutting depth. Particularly, a compound arc breaking mechanism (CABM), which integrates hydrodynamic force and mechanical motion, has been applied to control the discharge arc column in EACC, while also strengthening the debris expelling effect in the narrow discharge gap. The CABM implementation conditions were studied, based on arc column distortion images captured by a high-speed camera and simulation results of the flow field and debris distribution. A set of machining experiments was designed and conducted to optimize the performance of the proposed process. Finally, a SiC_p/Al metal matrix composite (MMC) space station workpiece was machined to verify the feasibility and efficiency of this process.

Keywords

Electrical arc contour cutting (EACC) / Electrical arc machining (EAM) / Compound arc breaking mechanism (CABM) / SiC_p/Al metal matrix composite (MMC) / High efficiency

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Guo-Jian He,Lin Gu,Ying-Mou Zhu,Ji-Peng Chen,Wan-Sheng Zhao,K. P. Rajurkar. Electrical arc contour cutting based on a compound arc breaking mechanism. Advances in Manufacturing, 2022, 10(4): 583-595 DOI:10.1007/s40436-022-00406-0

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