Simulation Analysis and Experimental Validation of Cathode Tool in Electrochemical Mill-Grinding of Ti6Al4V

Electrochemical mill-grinding (ECMG) is an ideal technical means to achieve an efficient and precise machining of titanium alloy monolithic structural parts. In the rough ECMG process, the selection of a reasonable cutting depth can improve the machining efficiency of the rough machining. Adopting a reasonable cathode tool structure can achieve a higher precision in the formation of the rough surface, reduce the finishing allowance and tool wear of subsequent finishing. With this aim, the present research proposed a cathode tool with a reasonable structure. Simulation results showed that the designed cathode tool presented a good uniformity of the flow field in the machining gap, which resulted in a higher precision in the formation of the rough surface. For experimental validation, a larger cutting depth and a designed cathode tool was employed to carry out the rough and finish machining experiments on a Ti6Al4V titanium alloy. The experimental results show that a good flatness of the sidewall of the rough-machining groove was obtained by this scheme. Furthermore, the machining surface exhibited no flow marks, and rough machining accounted for 92.37% of total removal. Moreover, measurement of the micro-morphology, roughness and elemental composition of the machined surface, and the effects of different machining parameters on the surface quality of titanium alloys, were studied.