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Abstract
Optimizing the electrical discharge machining (EDM) discharge energy parameters and machine tool control parameters for processing S-03 high-strength steel aerospace components is studied. The aim of this paper was to improve the machining efficient, with regard to the requirements of the recast layer thickness and surface roughness. The design of experiments method was used in the experiments. First of all, peak discharge current (ie) was confirmed to fulfill the requirement of surface roughness and recast thickness, becausei e is the uppermost parameter affecting both factors. Secondly, pulse on-time (t on) and open-circuit voltage (U) were in turn to be confirmed. Finally, the machine tool control parameters were adjusted to achieve optimized results regarding the machining efficiency, surface roughness, and recast thickness. This promising technology was advanced for manufacturing the integrated turbine disk in S-03 material. The researched parameters and experiments results concerning machining time, relative electrode wear rate (θ), and the quality of the integrated turbine disk are presented. The results show that: peak current 20A, pulse on-time 42 µs, open-circuit voltage 100V, duty factor 70%, electrode jump motion speed 10m/min, and electrode jump motion height 6mm are the best optimized parameters for S-03 high-strength steel.
Notes
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