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1 2018

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Applications of metallic composites in the automotive industry and their machining by the EDM

Bialo D., Peronczyk J., Skalski A., Skalski A.

Journal of KONES

2018

Vol. 25, No. 1

15--23

The article deals with the problems of application of aluminium matrix composites in car industry and electro discharge machining (EDM) of selected composites, which are used for engine pistons. Composites with Al+20%Si+3%Cu+1%Mg matrix were manufacturing by the powder metallurgy route in the process of cold compaction, degassing and hot extrusion. As the reinforcing phase Al2O3 particles with average size of 3, 9, 23 and 53 μm were used. Samples had constant reinforcing phase 5 and 10 % by volume. Electro discharge machining was performed using machine equipped with RLC generator. Four modes of energy of single discharge Ei in the range of 0.165 to 2.268 mJ were applied. EDM was carried out in a free – system. The main parameters determined after machining were volumetric productivity Vw (mm3 /min) and roughness of the machined surface expressed as Ra. It was shown that energy of single discharge influence mainly on the EDM process running. The higher was Ei, the higher were value of Vw. Increasing particle granularity from 3 to 53 μm caused decreasing in process productivity 13 to 19%. Ei affects the surface roughness during EDM. The value of Ra increases as this energy increases. When the size of reinforcing particles is growing, roughness parameter Ra is also growing.