| Aiming at solving the problems that the electrode wear is hard to be determined and the materialremoval rate is low in the ED-Milling machining, a novel machining method named controllablespark-induced combustion and ED-Milling machining is proposed. This machining method, in whichthe pulse oxygen gas blown throughout the rotating tubular electrode, uses chemical energy ofspark-inducd combustion to realize material removal during the oxygen supply and uses traditionalEDM occuring during the oxygen shutoff to accomplish surface finishing. It can acquire high materialremoval rate, low electrode relative wear rate and good processing quality.The main work of this paper are as follows:1）Establish a machining system to meet the needs of controllable spark-induced combustion andED-Milling machining.2）Under the same condition, the materail removal rate of controllable spark-induced combustionand ED-Milling machining is ten times higher than traditional ED-Milling, however, the electroderelative wear rate is very low, it can also acquire good processing quality.3)Use continuous photography and discharge waveforms to study machining micro-process, andstudy the characteristic of this machining method through surface micro-topography and elementcomposition. The result shows that the machining micro-process includes: discharge channel be setand high temperature activation region establishes, activation metal combusts and material beremoved, traditional ED-Milling finishing.4)Use ANSYS to simulate temperature field of traditional EDM machining and spark-inducedcombustion machining, and analyze the effects of them in the machining process. Compare thesimulation results with the experimental results to direct the process test.5)Research the effects of electrical parameters and non-electrical parameters to the materialremoval rate and electrode relative wear rate; use this machining method to machine GH4169, Cr12,TC4and YG6A respectively, by which can acquire a good machining result. |
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