The effect of the slope angle and the magnetic field on the surface quality of nickel-based superalloys in blasting erosion arc machining

Abstract

Electrical arc machining (EAM) is an efficient process for machining difficult-to-cut materials. However, limited research has been conducted on sloped surface machining within this context, constraining the further application for complex components. This study conducts bevel machining experiments, pointing out that the surface quality becomes unsatisfactory with the increasing bevel angle. The discharge condition is counted and analyzed, while the flow field and the removed particle movement of the discharge gap are simulated, demonstrating the primary factor contributing to the degradation of surface quality, namely the loss of flushing. This weakens both the plasma control effect and debris evacuation, leading to the poor discharge condition. To address this issue, the magnetic field is implemented in blasting erosion arc machining (BEAM). The application of a magnetic field effectively regulates the arc plasma, enhances debris expulsion, and significantly improves the discharge conditions, resulting in a smoother and more uniform sloped surface with a reduced recast layer thickness. This approach provides the possibility of applying BEAM to complex parts made of difficult-to-cut materials in aerospace and military industries.

Keywords

Blasting erosion arc machining (BEAM) / Surface quality / Machining angle / Magnetic field assisted

References

[1.] Zhang B, Zeng Y, Pang X, et al. Feasibility analysis and process characteristics of selective laser ablation assisted milling Inconel 718. Adv Manuf, 2022, 10(4): 495-519.

[2.] Chen J, Gu L, Zhao W, et al. Modeling of flow and debris ejection in blasting erosion arc machining in end milling mode. Adv Manuf, 2020, 8: 508-518.

[3.] Meshcheriakov G, Nosulenko V, Meshcheriakov N, et al. Physical and technological control of arc dimensional machining. CIRP Ann Manuf Tech, 1988, 37(1): 209-212.

[4.] Wei B, Trimmer A, Luo Y et al (2010) Advancement in high-speed electroerosion processes for machining tough metals. In: Proceedings of the 16th international symposium on electromachining, pp 193–196, Shanghai

[5.] Zhao W, Gu L, Xu H, et al. A novel high efficiency electrical erosion process—blasting erosion arc machining. Procedia CIRP, 2013, 6: 621-625.

[6.] Krotz H, Roth R, Wegener K. Experimental investigation and simulation of heat flux into metallic surfaces due to single discharges in micro-electrochemical arc machining (micro-ECAM). Int J Adv Manuf Technol, 2013, 68: 1267-1275.

[7.] Wang F, Liu Y, Zhang Y, et al. Compound machining of titanium alloy by super high speed EDM milling and arc machining. J Mater Process Technol, 2014, 214(3): 531-538.

[8.] Wu X, Liu Y, Zhang P, et al. Electrical discharge and arc milling with automatic tracking of optimal flushing direction: a novel high- efficiency compound machining method. Chin J Aeronaut, 2023, 37: 351.

[9.] Xu H, Gu L, Chen J, et al. Machining characteristics of nickel-based alloy with positive polarity blasting erosion arc machining. Int J Adv Manuf Technol, 2015, 79: 937-947.

[10.] Liu Z, Liu K, Dai X, et al. Milling performance of Inconel 718 based on DC short electric arc machining with graphite and W-Ag electrode materials. Int J Adv Manuf Technol, 2022, 122(5): 2253-2265.

[11.] Gu L, He G, Li K, et al. Improving surface quality in BEAM with optimized electrode. CIRP Ann Manuf Technol, 2022, 71: 165-168.

[12.] Kou Z, Han F, Wang G. Research on machining Ti6Al4V by high-speed electric arc milling with breaking arcs via mechanical-hydrodynamic coupling forces. J Mater Process Technol, 2019, 271: 499-509.

[13.] Gu L, Zhang F, Zhao W, et al. Investigation of hydrodynamic arc breaking mechanism in blasting erosion arc machining. CIRP Ann Manuf Technol, 2016, 65(1): 233-236.

[14.] Guo C, Wei D, Di S. Improving energy utilization efficiency of electrical discharge milling in titanium alloys machining. J Cent South Univ, 2016, 23: 2550-2557.

[15.] Li X, Li Z, Wu T, et al. Experimental research on short electric arc milling machining based on the mechanical-fluid coupling effect. Proc Inst Mech Eng Part B-J Eng Manuf, 2023, 237(9): 1353-1363.

[16.] He G, Gu L, Zhu Y, et al. Electrical arc contour cutting based on a compound arc breaking mechanism. Adv Manuf, 2022, 10: 583-595.

[17.] Nakano S, Shibayama T, Kunieda M et al (2005) Curved surface machining by dry EDM using 5-axis machine. In: Proceedings of JSPE semestrial meeting, pp 838–838, Tokyo

[18.] Fujiki M, Ni J, Shih AJ. Investigation of the effects of electrode orientation and fluid flow rate in near-dry EDM milling. Int J Mach Tool Manuf, 2009, 49(10): 749-758.

[19.] Fujiki M, Ni J, Shih AJ. Tool path planning for near-dry EDM milling with lead angle on curved surfaces. J Manuf Sci E-T Asme, 2011, 133(5): 051005.

[20.] Guo C, Sun S, Di S, et al. Experimental and simulation study of the ED-milling flow field to improve its machining performance. Int J Adv Manuf Technol, 2021, 113: 2513-2522.

[21.] Guo X, Tan L, Xie Z, et al. Simulation and experimentation of renewable dielectric gap flow fields in EDM. Int J Adv Manuf Technol, 2024, 130(3): 1935-1948.

[22.] Wang X, Guo H, Wu G, et al. Hydrodynamic arc moving mechanism in EDM of polycrystalline diamond. Mater Manuf Process, 2022, 37(14): 1652-1663.

[23.] Lin L, Liu Y, Xue W, et al. Improving the machined surface in electrochemical mill-grinding by particle tracking fluid simulation and experimental research. Phys Fluids, 2023, 35(12): 123319.

[24.] Gu L, Farhadi A, Zhu Y, et al. A novel tool design procedure for arc sweep machining technology. Mater Manuf Process, 2020, 35(1): 113-121.

[25.] Kou Z, Han F. Machining characteristics and removal mechanisms of moving electric arcs in high-speed EDM milling. J Manuf Process, 2018, 32: 676-684.

[26.] Jiang Y, Kong L, Ping X, et al. Utilizing a porous-electrode for the flushing fluid in electrical discharge machining. J Manuf Process, 2021, 62: 248-256.

[27.] Li K, Wang X, Jiang L, et al. Study of arc behavior and machining effects of the novel magnetic field assisted blasting erosion arc machining method. J Mater Process Tech, 2024, 323: 118227.

[28.] Lin Y, Lee H. Machining characteristics of magnetic force-assisted EDM. Int J Mach Tools Manuf, 2008, 48: 1179-1186.

[29.] Lin Y, Chen Y, Wang D, et al. Optimization of machining parameters in magnetic force assisted EDM based on taguchi method. J Mater Process Technol, 2009, 209: 3374-3383.

Funding

National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809(51975371)