水包油型乳化液钛合金TC4电火花加工特性研究

为解决钛合金在煤油介质中电火花加工效率低及在蒸馏水介质中加工表面质量差的问题,提出利用乳化剂将煤油和蒸馏水超声振动后形成水包油型乳化液作为工作介质的加工方法。分别以煤油、水包油型乳化液和蒸馏水为工作介质,对钛合金TC4进行放电加工试验,从加工效率、电极相对损耗率和表面质量三个方面,对比研究了不同工作介质中钛合金电火花加工的特性。试验结果表明：水包油型乳化液中的加工效率是煤油中加工效率的两倍左右,工件表面粗糙度值Ra比蒸馏水中的Ra值减小了15%~20%,加工后工件表面微裂纹较少,表面较平整,但其电极相对损耗率高。

Research on Titanium Alloy TC4 Electrical-discharge Machining Characteristics Using Oil-in-water Emulsion

To solve the problems for TC4 EDM, such as lower machining efficiency in kerosene and bad surface quality in distilled water, the kerosene and emulsifier were added into distilled water and vibrated by ultrasound to form oil-in-water emulsion herein. To study the characteristics of three kind of dielectrics used in TC4 EDM, kerosene, oil-in-water emulsion and distilled water were used as working dielectrics to machine titanium alloy, they were compared in aspects of MRR, electrode wearing rate (EWR) and surface quality. Results show that: two times higher machining efficiency in oil-in-water emulsion can be obtained than in kerosene and the surface roughness is decreased 15%~20% than in distilled water. After machining in oil-in-water emulsion, there are less surface microcracks on the workpiece, and its surface smoothness is better than the others machined in kerosene and distilled water, but the EWR is higher.