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Characterization and Parametric Optimization of Aluminum Alloy Using Short Electric Arc Milling

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Abstract

The objective of this present work is to find out the optimum level and influence of short electric arc milling (SEAM) process on material removal rate (MRR), relative tool wear ratio (RTWR) and deformation layer thickness (DLT). The mathematical model of the interaction of influencing factors was established by using the design expert software. The optimal level of input parameters such as voltage, pulse frequency, duty cycle, pressure of working medium is calculated by response surface center composite method to achieve maximum MRR and minimum RTWR and DLT. It is found that the effective discharge energy matches the hydrodynamic arc breaking mechanism, which can better control the MRR and RTWR. Similarly, the experimental results show that under the conditions of 32 V voltage, 70% duty cycle, 0.6 kHz pulse frequency and 0.4 MPa working medium pressure, the MRR of aviation aluminum alloy reaches 16,733 mm3/min and RTWR is limited to 1.549%. The obtained data can be utilized for the SEAM industry during the high efficiency machining of aluminum alloy.

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Acknowledgments

Over the course of my researching and writing this paper, I would like to express my thanks to all those who have helped me.

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Authors and Affiliations

  1. School of Electrical and Mechanical Engineering, Xinjiang Institute of Engineering, Urumqi, 830023, China

    Dan Song, Yong Huang & Zhang Zhihu

  2. Department of Industrial Engineering, University of Padua, 35131, Padua, Italy

    Kai Liu

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  1. Dan Song
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  2. Kai Liu
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  3. Yong Huang
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  4. Zhang Zhihu
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by SD, LK and HY. The first draft of the manuscript was written by SD and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Dan Song.

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Song, D., Liu, K., Huang, Y. et al. Characterization and Parametric Optimization of Aluminum Alloy Using Short Electric Arc Milling. J. of Materi Eng and Perform 33, 1262–1273 (2024). https://doi.org/10.1007/s11665-023-08061-7

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  • DOI: https://doi.org/10.1007/s11665-023-08061-7

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