Simulation and Experimental Investigation of Electrochemical Mill-grinding of GH4169 Alloy

Abstract

Electrochemical mill-grinding (ECMG) is a new method of compound machining inspired by numerical-control milling. A simple rodlike grinding wheel that rotates at high speed is used as the cathode and processes the workpiece along a set trajectory. Electrochemical milling and grinding are both at play in ECMG, making it possible to machine large amounts of material from the workpiece while benefitting from excellent machining flexibility. In this paper, to machine GH4169 alloy highly efficiently, four types of rodlike grinding wheel are designed, all with a diameter of 10.2 mm, and the machining flow field is simulated using ANSYS software. The maximum feed rate of each grinding wheel is measured under different values of voltage and electrolyte pressure, and a groove-machining experiment is performed in which a maximum feed rate of 2.3 mm/min and material removal rate of 25.883 mg/s are achieved for a cutting depth of 10 mm. The machining accuracy and surface quality of the grooves are then compared and analysed.