Numerical and experimental study on EDM drilling of Ti-Cu-Zr metallic glass considering energy efficiency

Abstract

Metallic glass offers several advantages, including high strength, corrosion resistance, and low coercivity. In precision machining fields like optical devices, medical devices, and micro-electromechanical systems, Ti-based metallic glass offers more advantages than Fe- and Zr-based metallic glass. However, its current machinability poses a challenge in meeting the requirements of precision metallic glass parts. To obtain the best machining performance, a thermophysical model of the EDM drilling process was established to simulate the temperature distribution on the surface of metal glass workpiece during EDM drilling. In addition, a new systematic method is utilized to calculate the characteristics of important machining holes, such as inlet and outlet overcut and inlet and outlet edge deviation. In this investigation, the maximum relative overcut and edge deviation are 8.59% and 7.23%, respectively, relative to the electrode radius. To improve the machining quality and machining stability, the slit width should be kept at an ideal value. Therefore, the recommended discharge current is 4–5 A, pulse duration is 50 μ s, and pulse duty ratio is 0.2 - 0.3 when EDM drilling of amorphous alloy. Based on this, the EDM drilling analysis method by numerical and experimental investigation for titanium-based metallic glass is put forward, which provides scientific theoretical guidance for the EDM of drilling it.