Modeling And Simulation Of SiC_p/al Composites In EDM

As a new type of advanced materials ,SiCp/Al composites has the advantages of high specific strength,good thermal stability and low linear thermal expansion coefficient. It is highly valued by the governments around the world and widely used in all kinds of industries such as aviation, astronautics and sports. However, because of its high hardness and high specific strength, it cannot be processed by traditional processing.As an effective non-traditional processing technology,electrical discharge machining is widely used in the machining of SiCp/Al composites.The distribution of particles in micro-hole EDM gap is an affecting factor of electrical discharge frequency and the location of discharge point. And it has great impact on the processing efficiency and the surface equality. Therefore the study on micro-hole EDM gap flow and the particle distribution is one of the most important way to improve processing efficiency ,ensure processing stability and micro-hole processing accuracy. The research on the temperature fields of electrical discharge machining has an important significance on comprehending the electrical discharge machining mechanism and predicting material removal rate, electrode wear and surface roughness.This paper makes a simulation on gap flow and temperature field regularities of SiCp/Al composites in the electrical discharge machining. A new method of electrode reforming is proposed. The particle concentration of gap flow is simulated by FLUENT. The simulation turns out that the electrode reforming method can decrease the particle concentration of gap flow, which is validated by experiment. Gap flow models under different rushed hydraulic pressures and different spindle speeds are established and distribution regulations of micro-hole EDM gap flow under different processing conditions are analyzed. The ANSYS is used for the simulation of the temperature field of single pulse discharge in EDM. The paper analyzes how the different electric parameters affect the pits discharge. Based on the results of the simulation of the temperature field of single pulse discharge in EDM, theory of continuous pulse discharge and layered removal method in EDM milling,models of materials removal rate and electrode wear are made and the results are proved by the related experiments.