Study on the Influence of the Processing Speed in the Generation of Complex Geometries in Aluminium Matrix Composites by Electrochemical Precision Machining

Abstract

Currently, an increasing demand for lightweight materials with a high strength can be observed. Potential materials, which fulfil these requirements, are particle reinforced aluminium matrix composites (AMCs). AMCs consist of an aluminium matrix, which is reinforced by ceramic particles. In a consequence, AMCs offer a strength, which is comparable to steel, along with a density, which is comparable to light metals. In the Collaborative Research Centre SFB 692 at Chemnitz University of Technology, AMCs are analysed under different research aspects. One of these aspects is the generation of complex geometries by Electrochemical Precision Machining (PECM).The investigated AMC consists of ENAW 2017, which is reinforced by 10% of SiC-particles. To achieve the desired complex geometry, the dissolution characteristic of the specific AMC was analysed. Furthermore, the achievable surface quality was characterised. Based on these fundamental results, processing strategies for generating complex geometries in AMCs by PECM were derived.In this study, the influence of the PECM processing speed on the resulting complex geometry is investigated. For that purpose, a model geometry based on a retarder was selected and realized. The resulting side gap and the front gap as a function of an increasing processing voltage and an increasing feed rate are presented. It can be stated that the side gap can be reduced by an increase in feed rate.