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Selected problems of electrical discharge machining (EDM) of metal composite materials applied in manufacturing of mechanical vehicles

Perończyk J.

Journal of KONES

2011

Vol. 18, No. 1

429-442

The paper presents examples of applications for metal composite materials on Al matrix reinforced with ceramic particles in the form of grains, fibre or whiskers in the automotive industry. Highlighted are the advantages and drawbacks of such composite materials and issues involved in shaping complete parts. Presence of hard and brittle ceramic particles in the Al alloy (given their sufficient concentration) significantly impacts on the physical, chemical and mechanical properties of the material and its suitability for shaping complete parts and constituting a surface layer (SL) with required properties. In making metal composite materials of Al alloys, various (including the latest) methods of casting are applied, often in combination with press molding in semi-fluid state, as well as powder metallurgy (P/M) methods. The final machining of functionally significant surfaces is done by machining (by all ways and variants). With presence of more than 5% (by volume) ceramic reinforcing particles it becomes necessary to use cutting blades of the so-called super hard materials, including composites of polycristalline diamond and diamond. This considerably increases manufacturing costs. Electrical discharge machining has proved to be an effective way for shaping metal parts, in all its variants: sinker (EDM), wire erosion (WEDM), micromachining (ěEDM), shaping by free electrode (REDM), discharge grinding (AEDM) and other. Cited in the paper are the results of own research connected with EDM and WEDM of Al alloys composite cast and reinforced with particles of Al2O3 (AlSi7Mg + 20%Al2O3) and a composite material produced by powder metallurgy methods (P/M) reinforced with various (maximum 10%) concentrations of Al2O3 or SiC or Si3N4. EDM and WEDM technological characteristics were defined for the studied materials in the form of regressive dependencies as statistical models of given indicators allowing for defining impact of machining parameters on shaping the indicators. In addition, there are selected photos of metallographic structures, enabling observation and evaluation of surface layer phase changes and chemical composition after EDM. The highly enlarged SEM micro-photos which are included show the geometric structure of machined surface, micro-cracks on borders of the composite material grains, presence of minor reinforcement particles adhering to the surface. This confirms the complex nature of electrical discharge machining mechanism taking place locally after very high temperatures and in a very short time, in presence of cold dielectric.