Hole quality and interelectrode gap dynamics during pulse current electrochemical deep hole drilling
Hole quality and interelectrode gap dynamics during pulse current electrochemical deep hole drilling
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DOI：
10.1007/s00170-006-0572-9
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发表时间：
2007-07
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影响因子：
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通讯作者：
D. S. Bilgi;V. Jain;R. Shekhar;A. V. Kulkarni
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文献类型：
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作者：
D. S. Bilgi;V. Jain;R. Shekhar;A. V. Kulkarni
本文介绍了镍基高温合金脉冲成形管电化学深孔钻削的试验研究。讨论了电压、进给速度、脉冲时间、占空比和刀尖裸露长度等5个工艺参数对深度平均径向过切量（DAROC）、金属质量去除率（MRRg）和金属线性去除率（MRRl）的影响。建立了描述工艺参数对DAROC、MRRg和MRRI影响的数学模型。该模型允许定量评价孔质量和工艺性能的同时。这一结果已被证实的轮廓的钻孔和MRRlobated实验。在所有实验中，钻取深度为26 mm且直径范围为2.205 mm至3.279 mm的通孔。脉冲电化学深孔钻削过程中普遍存在的极间间隙动力学现象解释了上述结果。通过这些实验确定的最佳参数可用于在镍基高温合金中高效钻削高质量的高深宽比深孔。
This paper presents the experimental investigation of pulse-current shaped-tube electrochemical deep hole drilling (PC-STED) of nickel-based superalloy. Influence of five process variables (voltage, tool feed rate, pulse on-time, duty cycle, and bare tip length of tool) on the responses, namely, depth-averaged radial overcut (DAROC), mass metal removal rate (MRRg) and linear metal removal rate (MRRl) have been discussed. Mathematical models have been developed to express the effects of the process parameters on DAROC, MRRgand MRRl. The proposed model permits quantitative evaluation of the hole quality and process performance simultaneously. The results have been confirmed for the profile of the drilled hole and MRRlobtained experimentally. In all the experiments, through holes of 26 mm depth and diameters ranging from 2.205 mm to 3.279 mm were drilled. The results have been explained by the interelectrode gap dynamics prevailing during pulse electrochemical deep hole drilling. Optimum parameters determined from these experiments can be used to efficiently drill high-quality deep holes of high aspect ratio in nickel-based superalloys.