Abstract
In order to solve the problem of low efficiency and poor surface quality, the method of powder mixed electrical discharge machining (PMEDM) was proposed for machining SiC/Al functionally graded materials (FGM). The thermo-electrical coupling simulation model was established. Based on the results of single-pulse discharge simulation, PMEDM material removal mechanism was researched. At the same time, the continuous multi-pulse EDM discharge dynamic simulation was studied. The position and the size of discharge crater and material removal rate (MRR) researched were discussed. Using PMEDM SiC/Al FGM, the crater depth is shallower and the radius is larger than traditional EDM. Under the condition of 5-wt% SiC/Al FGM, peak current 14 A, powder concentration 4 g/L, pulse width 175 μs, and pulse interval 75 μs, the maximum MRR error between simulation and experiment is 5.81%, and the minimum error is 4.13%. Compared with the traditional EDM, the efficiency of PMEDM is improved by 16.34%, and the surface roughness is reduced by 29.42%.
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