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Adaptive planetary control with auxiliary magnetic field method for fast EDM drilling

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Abstract

The existence of a thick recast layer on the surface of film cooling holes after fast electrical discharge machining (EDM) drilling is a critical problem in the manufacture of turbine blades. To suppress the generation of a recast layer and improve the machining efficiency, an adaptive planetary control with an auxiliary magnetic field (APCAMF) method is proposed to improve the machining quality of film cooling holes. The auxiliary magnetic field is used to concentrate the discharge energy and accelerate the removal of molten materials. Planetary movements are used to decrease the thickness of a recast layer that solidifies on the hole wall during machining. To reduce unnecessary planetary movements, planetary machining is combined with adaptive servo control. The adaptive control method uses a model that combines online identification with an indirect self-tuning regulator. The controller obtains the discharge status through a novel discharge state detector based on a programmable System-on-Chip (PSoC). While the discharge status is used as the input to the adaptive controller, the servo feedrate is used as the output. Parameters of planetary machining are determined by the effective feed distance and the proportion of short-circuit pulses. With a simple structure, the APCAMF scheme is easy to be implemented. Experiments showed that a rotating auxiliary magnetic field can effectively reduce the thickness of a recast layer as large as 33.53 μm in fast EDM drilling. The recast layer reduction rate of the APCAMF scheme is 73.47%, with the machining efficiency increased by 18.52%.

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Availability of data and materials

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

This paper uses a proprietary software and will be not available.

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Funding

This work is financially supported by National Natural Science Foundation of China (Grant No. 52075333, Grant No.51775341, Grant No.52175426), National Science and Technology Major Project (Grant No. 2018ZX04005001).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Minhang Dist, No.800 Dongchuan Rd, Shanghai, China

    Haoyu Chu, Zilun Li, Xuecheng Xi, Yaou Zhang & Wansheng Zhao

  2. State Key Laboratory of Mechanical System and Vibration, Shanghai, China

    Haoyu Chu, Zilun Li, Xuecheng Xi, Yaou Zhang & Wansheng Zhao

Authors
  1. Haoyu Chu
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  2. Zilun Li
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  3. Xuecheng Xi
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  4. Yaou Zhang
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  5. Wansheng Zhao
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Contributions

Haoyu Chu: methodology, conceptualization, software, validation, formal analysis, writing — original draft and editing. Zilun Li: formal analysis, software, validation. Xuecheng Xi: funding acquisition, supervision, writing — reviewing and editing. Yaou Zhang: formal analysis, validation. Wansheng Zhao: funding acquisition, supervision, writing — reviewing and editing.

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Correspondence to Wansheng Zhao.

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Chu, H., Li, Z., Xi, X. et al. Adaptive planetary control with auxiliary magnetic field method for fast EDM drilling. Int J Adv Manuf Technol 120, 2217–2227 (2022). https://doi.org/10.1007/s00170-022-08939-1

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  • DOI: https://doi.org/10.1007/s00170-022-08939-1

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