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Research on short electric arc–electrochemical combined machining performance of Ti–6Al–4V alloys using different electrode materials

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Abstract

Short electric arc–electrochemical combined machining (SEAECM) involves both short electric arc discharge and electrochemical dissolution processes, and the choice of electrode materials has an important impact on the respective machining performance of short electric arc machining (SEAM) and electrochemical machining (ECM). Therefore, this research compares the performance of three commonly used low-cost materials (brass, copper, and graphite) as electrodes in SEAECM. The effects of different process parameters (voltage, duty ratio, electrolyte concentration, and feedrate) on the material removal rate, electrode volume wear, surface roughness, and dimensional accuracy errors of the three electrodes in SEAECM are also investigated to determine the applicable occasions for different electrode materials. The results show that the physical properties of the electrode materials such as resistivity, thermal conductivity, and melting point have a significant effect on the machining results. The brass electrode has the highest wear and the lowest material removal rate for all parameters. The copper electrode has the most balanced machining performance, especially at low discharge energy, with low electrode wear and good surface quality. Graphite electrode shows machining potential at high discharge energy, but still requires coordination of SEAM and ECM to improve the surface quality. Overall, in SEAECM, the copper electrode is suitable for high surface quality machining at low discharge energy, and the graphite electrode is suitable for efficient and medium quality machining at higher discharge energy.

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Funding

This research was supported by the Tianshan Innovation Team Project (Grant No. 2022D14002) and the Natural Science Foundation of China (Grant No. 51765063).

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Authors and Affiliations

  1. School of Mechanical Engineering, Xinjiang University, Ürümqi, 830047, China

    Shengsheng Zhang, Guoyu Hu, Jianping Zhou, Lizhong Wang, Yan Xu, Xiangyu Dai, Jiahao Wang & Xinyang Ma

  2. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, China

    Lizhong Wang

  3. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, 710049, China

    Guoyu Hu

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  1. Shengsheng Zhang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by SZ, GH, JZ, LW, YX, XD, JW, XM. The first draft of the manuscript was written by SZ, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jianping Zhou or Lizhong Wang.

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The authors declare that they have no conflict of interest. The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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Technical Editor: Adriano Fagali de Souza.

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Zhang, S., Hu, G., Zhou, J. et al. Research on short electric arc–electrochemical combined machining performance of Ti–6Al–4V alloys using different electrode materials. J Braz. Soc. Mech. Sci. Eng. 44, 463 (2022). https://doi.org/10.1007/s40430-022-03766-7

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  • DOI: https://doi.org/10.1007/s40430-022-03766-7

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