Experimental Study on Machining Gap of Spark Assisted Chemical Engraving Process
Liu Guang;Tong Hao;He Suqin;Li Yong;Li Wenzhuo;School of Mechatronics and Automobile Engineering,Yantai University;Institute of Manufacturing Engineering,Department of Mechanical Engineering,Tsinghua University;Beijing Key Laboratory of Precision,Ultra-precision Manufacturing Equipment and Control;
To improve the machining effect of Zr O2 insulating ceramic as thermal barrier coatings(TBCs) on aeroengine turbine blades,machining experiments were carried out to explore the influence of different machining gaps on machining stability and efficiency in spark assisted chemical engraving(SACE) process. An electrode-alignment method was presented for giving a machining gap by use of image observation based on a charge coupled device,and the tests showed that the gap accuracy can be controlled within ±1 μm. Further,several experiments were conducted to evaluate and optimize the machining gap with specific processing parameters. The methods of ion sputtering and Matlab image processing were adopted to analyze removal areas from workpieces,and the range of optimum machining gap was gained according to the maximum removal area come from stable sparks. This research can provide the basis for optimizing SACE process.