Abstract
Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.
Highlights
metal matrix composites (MMCs) have outstanding advantages, but the performance of the two constituent materials differs
Electrolytic discharge machining (ECDM) is a technology that applies bubbles generated via electrolysis to form a gas film around electrodes and induces discharge melting and chemical corrosion between a tool and a workpiece [7]
Combining the advantages of the high surface quality produced by ultrasonic vibration of EC/DM and the high efficiency by grinding on MMCs, we constructed a method called two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge (2UE/DM) that functions under low current density and low voltage to improve the machining efficiency and quality of MMCs
Summary
MMCs have outstanding advantages, but the performance of the two constituent materials differs. Razfar [19] and Elhami [20] introduced vibration to a tool to machine glass microholes and found that ultrasonic vibration increased the frequency and probability of discharges and improved the material removal rate and surface quality [21]. Combining the advantages of the high surface quality produced by ultrasonic vibration of EC/DM and the high efficiency by grinding on MMCs, we constructed a method called two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge (2UE/DM) that functions under low current density and low voltage to improve the machining efficiency and quality of MMCs. During the processing, the ultrasonic vibration direction of the tool and workpiece are axial (Z direction) and tangential (X direction), respectively.
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