Electrical arc contour cutting based on a compound arc breaking mechanism

doi:10.1007/s40436-022-00406-0

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4): 583-595.doi: 10.1007/s40436-022-00406-0

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Electrical arc contour cutting based on a compound arc breaking mechanism

Guo-Jian He¹, Lin Gu¹, Ying-Mou Zhu¹, Ji-Peng Chen², Wan-Sheng Zhao¹, K. P. Rajurkar³

1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People's Republic of China;
2. School of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, 210037, People's Republic of China;
3. Center for Nontraditional Manufacturing Research, University of Nebraska-Lincoln, Lincoln, NE, USA

Received:2021-06-26 Revised:2021-10-22 Published:2022-11-05
Contact: Lin Gu E-mail:lgu@sjtu.edu.cn
Supported by:
The authors acknowledge the National Science Foundation of China (Grants Nos. 51235007 and 51575351) and the State Key Laboratory of Mechanical System and Vibration of China (Grant No. MSV201305) for their fnancial support of this research.

Abstract

Abstract: Electrical arc contour cutting (EACC) is a novel high-efficiency material cutting process that applies arc plasma to perform efficient and economical contour cutting of difficult-to-cut materials. Compared to conventional electrical arc machining (EAM), this process can remove the allowance of open structures and plates in bulk mode, rather than entirely in the form of debris. Compared with existing contour cutting methods, EACC possesses the advantages of high cutting efficiency and a deep cutting depth. Particularly, a compound arc breaking mechanism (CABM), which integrates hydrodynamic force and mechanical motion, has been applied to control the discharge arc column in EACC, while also strengthening the debris expelling effect in the narrow discharge gap. The CABM implementation conditions were studied, based on arc column distortion images captured by a high-speed camera and simulation results of the flow field and debris distribution. A set of machining experiments was designed and conducted to optimize the performance of the proposed process. Finally, a SiC_p/Al metal matrix composite (MMC) space station workpiece was machined to verify the feasibility and efficiency of this process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00406-0

Key words: Electrical arc contour cutting (EACC), Electrical arc machining (EAM), Compound arc breaking mechanism (CABM), SiC_p/Al metal matrix composite (MMC), High efficiency

Guo-Jian He, Lin Gu, Ying-Mou Zhu, Ji-Peng Chen, Wan-Sheng Zhao, K. P. Rajurkar. Electrical arc contour cutting based on a compound arc breaking mechanism[J]. Advances in Manufacturing, 2022, 10(4): 583-595.

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Electrical arc contour cutting based on a compound arc breaking mechanism

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