高体积分数SiCp/Al复合材料电解机械组合低磨损加工方法研究

doi:10.3969/j.issn.1004-132X.2025.04.012

摘要/Abstract

摘要： 为了解决高体积分数铝基碳化硅（SiCp/Al）复合材料在常规机械加工方法下存在的刀具磨损严重、表面质量差、加工效率低等问题，提出了电解机械组合的加工方法，开展了高体积分数（60%）SiCp/Al复合材料的组合加工试验。结果表明，在电解加工SiCp/Al复合材料中，随着表面铝基体的去除，碳化硅颗粒裸露分布在工件表面；电解加工后的工件表面与基体之间存在一定深度的过渡区，过渡区内的铝基体被局部去除，碳化硅颗粒受到的约束力减小；采用金刚石磨棒对电解加工后的过渡区进行机械加工时不发生铝基体黏附现象，金刚石磨棒几乎无磨损，工件加工表面损伤明显减少。电解机械组合加工可改善高体积分数SiCp/Al复合材料的可加工性。

关键词: 铝基碳化硅复合材料, 电解加工, 工具磨损, 金刚石磨棒

Abstract: To improve the problems of tool wear, poor surface quality and low machining efficiency of aluminum-based silicon carbide（SiCp/Al) composites with high volume fraction under conventional machining, an ECM-mechanical combined machining method was proposed, and the ECM-mechanical combined machining experiments of 60% volume fraction SiCp/Al composites were carried out. The results show that SiC particles are exposed on the surfaces with the removal of aluminum matrix. There is a certain depth of transition zone between the surface of the workpiece and the matrix after ECM, the aluminum matrix in the transition zone is locally removed, and the binding force of SiC particles is reduced. When the diamond grinding rod is used for machining the transition zone, the aluminum matrix adhesion phenomenon is not observed, the diamond grinding rod has almost no wear, and the surface damages are obviously reduced. The machinability of high volume fraction SiCp/Al composites may be improved by ECM-mechanical machining processes.

Key words: , aluminum-based silicon carbide composites（SiCp/Al), electrochemical machining(ECM), tool wear, diamond grinding rod

中图分类号:

TG662

何斌, 周星雨, 陆洪昱, 张俊飞, 丁凯, 李奇林, 雷卫宁. 高体积分数SiCp/Al复合材料电解机械组合低磨损加工方法研究[J]. 中国机械工程, 2025, 36(04): 753-759.

HE Bin, ZHOU Xingyu, LU Hongyu, ZHANG Junfei, DING Kai, LI Qilin, LEI Weining. Study on Low Wear Machining Method of High Volume Fraction SiCp/Al Composite Materials by ECM-mechanical Combined Machining Processes Method[J]. China Mechanical Engineering, 2025, 36(04): 753-759.

导出引用管理器 EndNote|Ris|BibTeX

链接本文: https://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2025.04.012

https://www.cmemo.org.cn/CN/Y2025/V36/I04/753

参考文献

［1］师祥利, 王雷雷, 张雷, 等. 碳化硅颗粒增强铝基复合材料在三自惯组中的精度提升研究［J］. 航空精密制造技术, 2024, 60(4):17-20.
SHI Xiangli, WANG Leilei, ZHANG Lei, et al. Research on Application of Silicon Carbide Particle Reinforced Aluminum Matrix Composite to Improve Navigation Accuracy of “Three-self” Inertial Measurement Combination［J］. Aviation Precision Manufacturing Technology, 2024, 60(4):17-20.
［2］陈智明, 辜勇, 钱静, 等. 铝基碳化硅复合材料的精密磨削研究［J］. 机械制造, 2021, 59(12):32-37.
CHEN Zhiming, GU Yong, QIAN Jing, et al. Research on the Precision Grinding of SiCp/Al Composite Material［J］. Machinery, 2021, 59(12):32-37.
［3］GU Peng，ZHU Chuanmin，MURA A ，et al. Grinding Performance and Theoretical Analysis for a High Volume Fraction SiCp/Al Composite［J］. Journal of Manufacturing Processes, 2022, 76:796-811.
［4］MILLER F, MONAGHAN J. Non-conventional Machining of Particle Reinforced Metal Matrix Composite［J］. International Journal of Machine Tools and Manufacture, 2000, 41(7):423-427.
［5］关佳亮, 张龙月, 刘书君, 等.不同体积分数SiCp/Al复合材料精密磨削试验研究［J］. 工具技术, 2019, 53(7):23-26.
GUAN Jialiang, ZHANG Longyue, LIU Shujun, et al. Experimental Study on Effect of Volume Fraction on Grinding Performance of SiCp/Al Composite ELID［J］. Tool Engineering, 2019, 53(7):23-26.
［6］GUO Sai, LU Shouxiang, ZHANG Bi, et al. Surface Integrity and Material Removal Mechanisms in High-speed Grinding of Al/SiCp Metal Matrix Composites［J］. International Journal of Machine Tools and Manufacture, 2022, 178:103906.
［7］向道辉, 马国峰, 张玉龙, 等. 超声辅助磨削碳化硅铝基复合材料改善砂轮堵塞的实验研究［J］. 制造技术与机床, 2015（6）:124-128.
XIANG Daohui, MA Guofeng, ZHANG Yulong, et al. Study on the Wheel Loading during Grinding SiCp/Al Composites by the Aid of Ultrasonic Vibration［J］. Manufacturing Technology & Machine Tool, 2015（6）:124-128.
［8］ZHANG Ke, GAO Qi, WANG Quanzhao. Milling Mechanism and Surface Quality of 20% Volume Fraction SiCp/Al Materials Treated by Natural Aging［J］. Silicon, 2023, 15:1883-1896.
［9］LIU Junwei, CHENG Kai, DING Hui, et al. An Investigation of the Influence of Phases Removal Ways on Surface Quality in Micro Milling SiCp/Al Composites［J］. Procedia CIRP, 2018, 71:59-64.
［10］LIU Chang, LI Cheng, XU Weiwei, et al. Variation Characteristics of Machinability in Drilling of SiC Particle Reinforced Aluminum Matrix（SiCp/Al) Composite with a Wide Range of Particle Volume Fractions［J］. The International Journal of Advanced Manufacturing Technology, 2022, 121(9/10):6285-6302.
［11］AO Sansan, QIN Xiangyang, LI Kangbai, et al. Effects of Process Parameters on Jet Electrochemical Machining of SiC Particle-reinforced Aluminum Matrix Composites［J］. The International Journal of Advanced Manufacturing Technology, 2021, 112:3351-3361.
［12］LIU Zhuang, GAO Changshui, QIU Yi, et al. Investigation on Electrochemical Jet Machining of High Volume Fraction SiCp/Al Composite［J］. International Journal of Electrochemical Science, 2020, 15(4):3164-3179.
［13］ZHANG Huizhen, LI Chao, ZHANG Lei, et al. Effect of Laser Pulse Energy Deposition Method on Nanosecond Laser Scanning Ablation of SiCp/AA2024 Composites［J］. Journal of Manufacturing Processes, 2022, 83:695-704.
［14］查慧婷, 冯平法, 张建富. 高体积分数SiCp/Al 复合材料旋转超声铣磨加工的试验研究［J］. 机械工程学报, 2017, 53(19), 107-113.
ZHA Huiting, FENG Pingfa, ZHANG Jianfu. An Experimental Study on Rotary Ultrasonic Machining of High Volume Fraction Silicon Carbide-reinforced Aluminum Matrix Composites（SiCp/Al)［J］. Journal of Mechanical Engineering, 2017, 53(19), 107-113.
［15］ZHAO Guolong, MAO Pengcheng, LI Liang, et al. Micro-milling of 65 vol% SiCp/Al Composites with a Novel Laser Assisted Hybrid Process［J］. Ceramics International, 2020, 46(16):26121-26128.
［16］REDDY K S N, KWANG-SUP S, YANG M. Experimental Study of Surface Integrity during End Milling of Al/SiC Particulate Metal-matrix Composites［J］. Journal of Materials Processing Technology, 2007, 201(1):574-579.
［17］XIAO Han, XU Dongdong, AXINTE D, et al. On Understanding the Specific Cutting Mechanisms Governing the Workpiece Surface Integrity in Metal Matrix Composites Machining［J］. Journal of Materials Processing Technology, 2021, 288:116875.

[1]	严丁虎, 赵建社, 张昌昊, 高伟正, 朱寅, . 阵列变截面球槽结构电解加工流场设计及试验研究[J]. 中国机械工程, 2023, 34(23): 2824-2831.
[2]	王陈, 赵建社, 强智明, 张昌昊, 柳世豪, . 振动进给对表面小微结构电解加工流场的影响[J]. 中国机械工程, 2023, 34(10): 1191-1198.
[3]	张晓博, 朱栋. 长窄型薄壁叶片的套料电解加工[J]. 中国机械工程, 2022, 33(07): 797-803，810.
[4]	王轶禹, 赵建社, 谷民凯, 纪涛. 渐开线内花键电解加工流场设计及工艺稳定性研究[J]. 中国机械工程, 2021, 32(13): 1562-1570.
[5]	童文俊;王明环;邱国志;许雪峰. 摩擦副表面气膜屏蔽微细电解加工微织构及摩擦性能分析[J]. 中国机械工程, 2020, 31(11): 1331-1336.
[6]	王峰1,2;赵建社1;刘鼎明1;范延涛1;田宗军1. 钛合金深窄槽可控振动辅助电解加工试验研究[J]. 中国机械工程, 2019, 30(20): 2395-2402.
[7]	徐波1,2;干为民1,2;何亚峰1,2;李文静3;王祥志1,2. 阶梯孔数控电解镗孔加工的阴极设计及试验研究[J]. 中国机械工程, 2019, 30(12): 1498-1506.
[8]	周小超1,2;陈远龙1;侯亭波1;王壮壮1. 基于气液两相流模型的电解加工多场耦合仿真[J]. 中国机械工程, 2019, 30(10): 1135-1141.
[9]	刘玉杰, 赵建社, 干为民, 祈璐. 轻量化阶梯孔结构电解加工试验研究[J]. 中国机械工程, 2015, 26(11): 1429-1433,1515.
[10]	万能, 杜珂, 高瑾宇, 陈涛. 面向叶片电解加工分析的等几何方法[J]. 中国机械工程, 2015, 26(10): 1368-1373.
[11]	赵建社, 李龙, 王峰, 肖雄. 振动进给对微尺度群缝电解加工过程的影响[J]. 中国机械工程, 2015, 26(1): 44-48,78.
[12]	刘嘉, 朱栋, 万龙凯, 朱荻. 整体叶盘电解加工移动密封阴极设计与试验[J]. 中国机械工程, 2014, 25(14): 1847-1851.
[13]	刘德营1, 2, 傅秀清1, 康敏1, 董朝盼1. 基于有限元法的球形数控电解加工工艺试验研究[J]. 中国机械工程, 2013, 24(6): 746-750.
[14]	王峰, 赵建社, 江琴, 肖雄. 基于电场仿真的微尺度群缝电解加工技术研究[J]. 中国机械工程, 2013, 24(23): 3154-3158.
[15]	孙伦业, 徐正扬, 朱荻. 基于叶栅通道可加工性分析的整体叶盘径向电解加工阴极设计及实验[J]. 中国机械工程, 2013, 24(09): 1137-1141.