摘要
以钛合金Ti-6Al-4V(TC4)为研究对象,建立工艺特征参数(铣削深度、铣削宽度、电极直径)与铣削面积的数学模型,揭示了各特征参数与铣削面积的数学关系.开展电弧铣削实验,研究铣削面积对加工电流、加工质量和加工效率的影响.结果表明:特征参数的变化影响了材料蚀除速率,致使电弧放电能量发生变化,进而影响热影响层和重铸层的厚度;平均峰值电流、表面粗糙度和热影响层厚度与铣削面积呈正相关,而允许的最大进给速度与铣削面积呈负相关;直流电压20 V、铣削深度3 mm、铣削宽度2 mm、主轴转速1 000 r/min时,表面质量最佳,表面粗糙度29.31 μm,热影响层厚88.24 µm,材料去除率最大为4 996.2 mm3/min.通过铣削面积的分析有助于后续电弧铣削加工工艺调控和优化.
Abstract
This paper takes titanium alloy Ti-6Al-4V(TC4)as the research object,establishes the mathematical model of process characteristic parameters(milling depth,milling width,electrode diameter)and milling area,and reveals the mathematical relationship between each characteristic parameter and milling area.Arc milling experiments were carried out to study the effect of milling area on processing current,processing quality and processing efficiency.The results show that:changes in the characteristic parameters affect the material etching rate,resulting in changes in the arc discharge energy,which in turn affects the thickness of the heat-affected layer and the recast layer;the average peak current,surface roughness value and the thickness of the heat-affected layer are positively correlated with the milling area,while the maximum permissible feed rate is negatively correlated with the milling area;under the condition of DC voltage of 20 V,the milling depth is 3 mm,the milling width is 2 mm,and the spindle speed is 1 000 r/min,the surface quality is the best,the surface roughness value is 29.31 µm,the thickness of heat-affected layer is 88.24 µm,and the maximum material removal rate is 4 996.2 mm3/min.It is proved that the analysis of the milling area is more helpful for the subsequent arc milling machining process regulation and optimization.
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