Titanium alloy materials have the characteristics of high strength, high plasticity, high toughness, high modulus, high damage tolerance, etc. The conventional turning and milling machining cannot reach the shape and size required by the design. Because electrolytic machining has the advantages of short-term and high efficiency, it is usually not limited by what kind of machining material it is. Therefore, it can be used as an ideal process method for machining titanium alloy materials. This article combines the actual introduction of how to use electrolytic method to process to meet the design requirements The product.
1.Design and manufacture of cathode
Due to the small size and complex shape of the processed products, and the need to consider the discharge gap of the electrode and the uniformity of the electrolytic flow field, the electrode design and manufacturing aspects need to be explored by actual electrolysis parameters. The physical electrode is shown in Figure 1:
2.Machining gap
During the electrolytic machining, the smaller the discharge gap and the better the surface quality, the higher the machining accuracy. During the electrolytic machining, the cathode is always fed and the anode is continuously dissolved. In the electrolytic machining process, the machining voltage and feed rate have an important influence on the machining surface quality and machining accuracy, so it is necessary to study the distribution gap. By adjusting the voltage, feed speed and selecting the appropriate electrolyte, the machining gap can be effectively controlled.
3.Selection of machining electrolyte
NaCl is a strong electrolyte, which can be almost completely ionized into Na + and Cl- ions in aqueous solution, and can coexist with H + and OH- plasma in water. Voltage, feed speed and optimized electrode structure will result in better surface quality and higher precision of the processed products. When NaCl is used as the electrolyte solute, its concentration is generally controlled at 10% -14%. When the surface quality requirements are high, it is generally controlled at less than 10%, and the machining temperature is usually controlled at the 14% concentration used this time. The NaCl solution was used as the electrolyte in this study. At the same time in order to ensure the effective use of electrolyte.
4.Insulation isolation of non-processed surface
In the process of electrolytic machining, in order to protect some non-machined parts so that it does not produce pitting corrosion, some insulation protection methods are usually adopted. After practice, it was finally determined to use electrostatic spraying method, which not only can effectively prevent the electrolyte from contacting the non-machined surface, and to play a role in separating stray currents, but also the sprayed non-metallic insulating layer is thin and the paste is more reliable It will not melt and fall off due to the high temperature generated by electrolysis, and it can be used multiple times in one spray.
After completing the selection of the electrolyte, the determination of the machining parameters, the spraying of the insulating protective layer, combined with the necessary indexing fixture, and after the adjustment and alignment and other preliminary preparations, the formal products were processed, and the actual products were processed. The effect is shown in Figure 2. After inspection, the actual machining size can reach the accuracy and size required by the design. Compared with the EDM process, its machining efficiency is increased by more than 95%, which not only improves production efficiency, but also saves production costs, and a lot of manpower and material resources, avoiding unnecessary waste of resources. Electrolytic machining When electrolytically machining titanium alloy products, as long as the correct machining electrode is designed, the machining parameters are reasonably selected, the machining electrolyte is properly prepared, and the ideal insulation protection method is adopted, the product meeting the design requirements can be efficiently processed in a short time.
