Skip to main content
SpringerLink
Log in

An analysis of the tool electrode working mechanism of grinding-aided electrochemical discharge machining of MMCs

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The working mechanism of the tool electrode in grinding-aided electrochemical discharge machining (G-ECDM) of metal matrix composites process has been studied in this paper. A series of experiments have been conducted to study tool electrode clogging and damage under different processing conditions. Moreover, the grit volume fractions and average grit height of the G-ECDM tool electrode have been studied to discover the working mechanism of the tool. The experimental results have shown that in the G-ECDM situation, though it is possible for the grinding effect to cause tool clogging, the clogged materials may be removed by the polarity spark effect and thus a stable processing condition can be obtained. Moreover, the tool life of G-ECDM is much longer than that of ECDM. The reason for this phenomenon could be that the binding materials between the diamond grits of the tool surface are potentially protected by the clogged materials during the process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Sharma P, Khanduja D, Sharma S (2014) Tribological and mechanical behavior of particulate aluminum matrix composites. J Reinf Plast Compos 33(23):2192–2202

    Article  Google Scholar 

  2. Marsh G (2003) Next step for automotive materials. Mater Today 6(4):36–43

    Article  Google Scholar 

  3. Akbari MK, Baharvandi HR, Shirvanimoghaddam K (2015) Tensile and fracture behavior of nano/micro TiB2 particle reinforced casting A356 aluminum alloy composites. Mater Des 66:150–161

    Article  Google Scholar 

  4. Shirvanimoghaddam K, Khayyam H, Abdizadeh H, Akbari MK, Pakseresht AH, Abdi F, Abbasi A, Naebe M (2016) Effect of B 4 C, TiB2 and ZrSiO4 ceramic particles on mechanical properties of aluminium matrix composites: experimental investigation and predictive modelling. Ceram Int 42(5):6206–6220

    Article  Google Scholar 

  5. Nicholls CJ, Boswell B, Davies IJ, Islam MN (2017) Review of machining metal matrix composites. Int J Adv Manuf Technol 90(9–12):2429–2441

    Article  Google Scholar 

  6. Zhao W, Huang S-J, Wu Y-J, Kang C-W (2017) Particle size and particle percentage effect of AZ61/SiCp magnesium matrix micro- and nano-composites on their mechanical properties due to extrusion and subsequent annealing. Metals 7(8):293

    Article  Google Scholar 

  7. Si C, Tang X, Zhang X, Wang J, Wu W (2017) Microstructure and mechanical properties of particle reinforced metal matrix composites prepared by gas-solid two-phase atomization and deposition technology. Mater Lett 201:78–81

    Article  Google Scholar 

  8. Ciftci I, Turker M, Seker U (2004) CBN cutting tool wear during machining of particulate reinforced MMCs. Wear 257(9):1041–1046

    Article  Google Scholar 

  9. Aramesh M, Attia HM, Kishawy HA, Balazinski M (2017) Observation of a unique wear morphology of cBN inserts during machining of titanium metal matrix composites (Ti-MMCs); leading to new insights into their machinability. Int J Adv Manuf Technol 92(1–4):519–530

    Article  Google Scholar 

  10. Ilio AD, Paoletti A (2000) A comparison between conventional abrasives and superabrasives in grinding of SiC-aluminium composites. Int J Mach Tool Manu 40(2):173–184

    Article  Google Scholar 

  11. Yue TM, Lau WS (1996) Pulsed Nd:YAG laser cutting of Al/Li/SiC metal matrix composites. Adv Manuf Process 11(1):17–29

    Article  Google Scholar 

  12. Zhong Z, Hung NP (2000) Diamond turning and grinding of aluminum-based metal matrix composites. Adv Manuf Process 15(6):853–865

    Article  Google Scholar 

  13. Ahamed AR, Asokan P, Aravindan S, Prakash MK (2010) Drilling of hybrid Al-5%SiC-5%BC metal matrix composites. Int J Adv Manuf Technol 49(9–12):871–877

    Article  Google Scholar 

  14. Li X, Bai F, Fu Y (2017) The small hole helical mill-grinding process and application in high volume fraction SiCp/Al MMCs. Int J Adv Manuf Technol 91(9–12):3007–3014

    Article  Google Scholar 

  15. Xiong Y, Wang W, Jiang R, Lin K, Song G (2016) Tool wear mechanisms for milling in situ TiB2 particle-reinforced Al matrix composites. Int J Adv Manuf Technol 86(9–12):1–10

    Google Scholar 

  16. Kong X, Zhang H, Yang L, Chi G, Wang Y (2016) Carbide tool wear mechanisms in laser-assisted machining of metal matrix composites. Int J Adv Manuf Technol 85(1–4):365–379

    Article  Google Scholar 

  17. Kök M, Kanca E, Eyercioğlu Ö (2011) Prediction of surface roughness in abrasive waterjet machining of particle reinforced MMCs using genetic expression programming. Int J Adv Manuf Technol 55(9–12):955–968

    Article  Google Scholar 

  18. Hreha P, Radvanská A, Hloch S, Peržel V, Królczyk G, Monková K (2015) Determination of vibration frequency depending on abrasive mass flow rate during abrasive water jet cutting. Int J Adv Manuf Technol 77(1–4):763–774

    Article  Google Scholar 

  19. Mohan B, Rajadurai A, Satyanarayana KG (2004) Electric discharge machining of Al–SiC metal matrix composites using rotary tube electrode. J Mater Process Technol 153–154(1):978–985

    Article  Google Scholar 

  20. Ahamed AR, Asokan P, Aravindan S (2009) EDM of hybrid Al–SiC p –B 4 C p and Al–SiC p –glass p MMCs. Int J Adv Manuf Technol 44(5–6):520–528

    Article  Google Scholar 

  21. Hourmand M, Farahany S, Sarhan AAD, Noordin MY (2015) Investigating the electrical discharge machining (EDM) parameter effects on Al-Mg 2 Si metal matrix composite (MMC) for high material removal rate (MRR) and less EWR–RSM approach. Int J Adv Manuf Technol 77(5–8):831–838

    Article  Google Scholar 

  22. Garg RK, Singh KK, Sachdeva A, Sharma VS, Ojha K, Singh S (2010) Review of research work in sinking EDM and WEDM on metal matrix composite materials. Int J Adv Manuf Technol 50(5–8):611–624

    Article  Google Scholar 

  23. Yan BH, Tsai HC, Huang FY, Long CL (2005) Examination of wire electrical discharge machining of Al 2 O 3 p/6061Al composites. Int J Mach Tool Manu 45(3):251–259

    Article  Google Scholar 

  24. Rao TB, Krishna AG (2014) Selection of optimal process parameters in WEDM while machining Al7075/SiCp metal matrix composites. Int J Adv Manuf Technol 73(1–4):299–314

    Article  Google Scholar 

  25. Rao SR (2012) Effect of process variables on metal removal rate in electrochemical machining of Al-B4C composites. Arch Appl Sci Res

  26. Rao SR, Padmanabhan G, Naidu KM, Reddy AR (2014) Parametric study for radial over cut in electrochemical drilling of Al-5%B 4 C p composites ☆. Procedia Eng 97:1004–1011

    Article  Google Scholar 

  27. Liu JW, Chen GX, Yue TM, Guo ZN (2012) Single pulse study of electrochemical discharge machining of metal matrix composites. Appl Mech Mater 200:536–539

    Article  Google Scholar 

  28. Praneetpongrung C, Fukuzawa Y, Nagasawa S, Yamashita K (2010) Effects of the EDM combined ultrasonic vibration on the machining properties of Si3N4. Mater Trans 51(11):2113–2120

    Article  Google Scholar 

  29. Sidhu SS, Batish A, Kumar S (2014) Study of surface properties in particulate-reinforced metal matrix composites (MMCs) using powder-mixed electrical discharge machining (EDM). Adv Manuf Process 29(1):46–52

    Article  Google Scholar 

  30. Kumar H (2015) Development of mirror like surface characteristics using nano powder mixed electric discharge machining (NPMEDM). Int J Adv Manuf Technol 76(1–4):105–113

    Article  Google Scholar 

  31. Pramanik A, Basak AK, Islam MN (2015) Effect of reinforced particle size on wire EDM of MMCs. Int J Mach Mach Mater 17(2):139

    Google Scholar 

  32. Hocheng H, Lei WT, Hsu HS (1997) Preliminary study of material removal in electrical-discharge machining of SiC/Al. J Mater Process Technol 63(1–3):813–818

    Article  Google Scholar 

  33. Mahdavinejad RA, Mahdavinejad A (2005) ED machining of WC–Co. J Mater Process Technol 162(10):637–643

    Article  Google Scholar 

  34. Lohrengel MM, Rataj KP, Münninghoff T (2016) Electrochemical machining—mechanisms of anodic dissolution. Electrochim Acta 201:348–353

    Article  Google Scholar 

  35. Liu JW, Yue TM, Guo ZN (2010) An analysis of the discharge mechanism in electrochemical discharge machining of particulate reinforced metal matrix composites. Int J Mach Tool Manu 50(1):86–96

    Article  Google Scholar 

  36. Liu JW, Yue TM, Guo ZN (2013) Grinding-aided electrochemical discharge machining of particulate reinforced metal matrix composites. Int J Adv Manuf Technol 68(9–12):2349–2357

    Article  Google Scholar 

Download references

Funding

This research was supported by the National Natural Science Foundation of China (51675105), the Special Support Plan of the Guangdong province (2014TQ01X542), the Natural Science Foundation of Guangdong province (2017A0330313330), the Equipment pre-research foundation (61409230304), and the Fundamental Research Funds for the Central Universities (2015ZZ080).

Author information

Authors and Affiliations

  1. School of Electromechanical Engineering, Guangdong University of Technology, No.100 Waihuanxi Road, Guangzhou Higher Education Mega Center, Panyu District, Guangzhou, 510006, People’s Republic of China

    Jiangwen Liu, Zhibiao Lin, Zhongning Guo & Shuzhen Jiang

  2. The Advanced Manufacturing Technology Research Centre, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Hong Kong

    Taiman Yue

Authors
  1. Jiangwen Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhibiao Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Taiman Yue
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhongning Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shuzhen Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Shuzhen Jiang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, J., Lin, Z., Yue, T. et al. An analysis of the tool electrode working mechanism of grinding-aided electrochemical discharge machining of MMCs. Int J Adv Manuf Technol 99, 1369–1378 (2018). https://doi.org/10.1007/s00170-018-2591-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2591-8

Keywords

Search

Navigation