Abstract
SiCp/Al, as a new material, is widely used for its excellent wear resistance, corrosion resistance and other properties. Micro-holes are important but difficult to obtain on this ceramic material especially in curved surface. In this paper, taking micro bearing bush as an example, a micro-EDM and in-situ micro-reaming method is put forward for preparing micro through holes and micro eccentric holes on SiCp/Al cambered surface, without secondary clamping or tool change. High machining efficiency, low wear and no recasting layer can be achieved by this method. Here, machining characteristics is studied in hole micro-EDM on SiCp/Al, small taper and high efficiency machining is realized by comparing four electrical discharge drilling technique. Carbon deposition and tool wear are related to electrical parameters according to experimental exploration. After determining the discharge gap, taper and recast layer thickness, a segmented tool is designed, which can use the lower part to perform micro-EDM with the taper of 1.04°, MRR is 0.069 mm3/min, and the TWR is 3.22%. Then only needs to continue feeding the tool, the upper part of the tool can be used to achieve reaming, which can fully remove the recast layer, and decreases the roughness of hole wall from Ra 1.452 μm to Ra 0.803 μm.
Similar content being viewed by others
References
Cheng, S. Y., Cao, Q., Bao, J. X., & Zhang, G. (2019). Research and development of medium/high volume fraction SiCp/Al composites. Chinese Optics, 12, 1064–1075.
Ramnath, B. V., Elanchezhian, C., Annamalai, R. M., Aravind, S., Atreya, T. S. A., Vignesh, V., & Subramanian, C. (2014). Aluminium metal matrix composites—a review. Reviews on Advanced Materials Science, 38(1), 55–60.
Ozben, T., Kilickap, E., & Cakir, O. (2008). Investigation of mechanical and machinability properties of SiC particle reinforced Al-MMC. Journal of Materials Processing Technology, 198, 220–225.
Tosun, G., & Muratoglu, M. (2004). The drilling of an Al/SiCp metal-matrix composites. part 1: microstructure. Composites Science and Technology, 64, 299–308.
Chen, J. P., Gu, L., & He, G. J. (2020). A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites. Advances in Manufacturing, 8, 279–315.
Chang, L., Xu, W. W., Yan, J., Jiang, X. G., & Tao, Y. (2020). Mechanistic force modeling in drilling of SiCp/Al matrix composites considering a comprehensive abrasive particle model. International Journal of Advanced Manufacturing Technology, 109, 421–442.
Xiang, J. F., Pang, S. Q., Xie, L. J., Gao, F. N., Hu, X., Yi, J., & Hu, F. (2018). Mechanism-based FE simulation of tool wear in diamond drilling of SiCp/Al composites. Materials, 11, 252.
Xiang, J. F., Xie, L. J., Gao, F. N., Yi, J., Pang, S. Q., & Wang, X. B. (2018). Diamond tools wear in drilling of SiCp/Al matrix composites containing copper. Ceramics International, 44, 5341–5351.
Huang, S. T., Li, C., Xu, L. F., Guo, L., & Yu, X. L. (2019). Variation characteristic of drilling force and influence of cutting parameter of SiCp/Al composite thin-walled workpiece. Advances in Manufacturing, 7, 288–302.
Zha, H. T., Zhang, J. F., & Feng, P. F. (2017). An experimental study on rotary ultrasonic drilling small-diameter holes of high volume fraction silicon carbide-reinforced aluminum matrix composites (SiCp/Al). 14th International Bhurban Conference on Applied Sciences and Technology, 34–39
Ao, S. S., Qin, X. Y., Li, K. B., & Luo, Z. (2021). Effects of process parameters on jet electrochemical machining of SiC particle-reinforced aluminum matrix composites. International Journal of Advanced Manufacturing Technology, 112, 3351–3361.
Chen, J. P., Gu, L., Zhao, W. S., & Guagliano, M. (2020). Simulation of temperature distribution and discharge crater of SiCp/Al composites in a single-pulsed arc discharge. Chinese Journal of Aeronautics, 34, 37–46.
Padhee, S., Pani, S., & Mahapatra, S. S. (2012). A parametric study on laser drilling of Al/SiCp metal-matrix composite. Proceedings of the Institution of Mechanical Engineers Part B-journal of Engineering Manufacture, 226, 76–91.
Hou, S. J., & Bai, J. C. (2021). A geometric prediction model of surface morphology in micro-EDM considering stochastic characteristics of discharge crater size. International Journal of Advanced Manufacturing Technology, 117, 1147–1162.
Kliuev, M., Florio, K., Akbari, M., & Wegener, K. (2019). Influence of energy fraction in EDM drilling of Inconel 718 by statistical analysis and finite element crater-modelling. Journal of Manufacturing Processes, 40, 84–93.
Liu, Y., Wang, B. C., Zhang, W. C., Zhang, S. F., Ma, F. J., Yang, D. P., & Sha, Z. H. (2019). Study on thermal erosion process of SiCp/Al composite material in EDM. 5th International Conference on Mechanical Engineering and Automation Science, 692, 012012.
Seo, Y. W., Kim, D., & Ramulu, M. (2006). Electrical discharge machining of functionally graded 15–35 vol% SiCp/Al composites. Materials and Manufacturing Processes, 21, 479–487.
Zhang, Z., Zhang, Y., Lin, L. Q., Wu, J. H., Yu, H. S., Pan, X., Li, G. L., Wu, J., & Xue, T. (2021). Study on productivity and aerosol emissions of magnetic fi eld-assisted EDM process of SiCp/Al composite with high volume fractions. Journal of Cleaner Production, 292, 126018.
Zhou, T. F., Zhou, C. H., Liang, Z. Q., & Wang, X. B. (2018). Machining mechanism in tilt electrical discharge milling for lens mold. International Journal of Advanced Manufacturing Technology, 95, 2747–2755.
Machno, M. (2020). Investigation of the machinability of the inconel 718 superalloy during the electrical discharge drilling process. Materials, 13, 3392.
Xu, B., Chen, S. G., Liang, X., Lei, J. G., Shi, H. Y., Fu, L. Y., Yang, J., Peng, T. J., Zhao, H., & Zhu, L. K. (2020). Recast layer removal of 304 stainless steel by combining micro-EDM with negative polarity micro-EDM. International Journal of Advanced Manufacturing Technology, 107, 4713–4723.
Acknowledgements
This research work is funded by National Natural Science Foundation of China [Grant number 52175390 and 52075130].
Author information
Authors and Affiliations
Corresponding authors
Ethics declarations
Conflict of Interest
The authors declare that we have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Gong, S., Wang, H., He, X. et al. One Step Fabrication of Micro-hole on SiCp/Al Cambered Surface by Micro-EDM and Mechanical-reaming Combined Machining. Int. J. of Precis. Eng. and Manuf.-Green Tech. 10, 891–903 (2023). https://doi.org/10.1007/s40684-022-00474-4
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40684-022-00474-4