Abstract Electrochemical discharge machining (ECDM) is a well-known process for machining of particulate reinforced metal matrix composites (MMCs). However, ECDM process suffers several drawbacks such as the lower material removal rate (MRR), high risks of tool wear rate (TWR) and relatively poor surface quality, etc. This study proposes a kind of electrochemical discharge grinding machining (ECDGM) method which employs a special shaped tool electrode. During the process, not only the can the hybrid action of electrochemical dissolution, spark erosion, and abrasive grinding improve the performance of machining MMCs, but also the special shaped of the tool electrode can be used to discharge the machined debris. And thus a higher machining efficiency and lower TWR can be obtained. The performance of developed process was conducted on machining of SiC particulate reinforced aluminum workpiece. The role of peak curre+nt, pulse duration, duty cycle, rotary speed and abrasive grit size has been investigated on MMR and TWR using the nonabrasive round electrode, abrasive round electrode, and abrasive shaped electrode respectively. The experimental results showed that using the shaped abrasive electrode for machining MMCs can achieve a higher MRR and lower TWR, as compared to the non-abrasive round electrode, abrasive round electrode. Besides, the orthogonal method was employed to analyze the relative importance of the machining parameters on MRR and TWR, it has been observed that MRR is affected by the processing parameters following the order of rotary speed > peak current > duty cycle > pulse duration, and TWR is following the order of peak current > duty cycle > pulse duration > rotary speed.

中文翻译：

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使用烧结青铜/金刚石成形磨具对金属基复合材料进行电化学放电磨削

摘要 电化学放电加工 (ECDM) 是众所周知的颗粒增强金属基复合材料 (MMC) 加工工艺。然而，ECDM 工艺存在材料去除率 (MRR) 较低、刀具磨损率 (TWR) 风险高和表面质量相对较差等缺点。本研究提出了一种电化学放电磨削加工 (ECDGM) 方法。采用特殊形状的工具电极。在此过程中，不仅可以通过电化学溶解、电火花腐蚀和磨料磨削的混合作用提高加工MMCs的性能，而且可以利用特殊形状的工具电极将加工后的碎屑排出。因此可以获得更高的加工效率和更低的TWR。对碳化硅颗粒增强铝工件的加工进行了所开发工艺的性能。分别使用非磨料圆形电极、磨料圆形电极和磨料成型电极在 MMR 和 TWR 上研究了峰值电流+nt、脉冲持续时间、占空比、旋转速度和磨料粒度的作用。实验结果表明，与非磨料圆形电极、磨料圆形电极相比，使用成型磨料电极加工MMC可以实现更高的MRR和更低的TWR。此外，采用正交方法分析加工参数对MRR和TWR的相对重要性，观察到MRR受加工参数的影响顺序为转速>峰值电流>占空比>脉冲持续时间，