关键词：铝基碳化硅复合材料；电解加工；工具磨损；金刚石磨棒

中图分类号：TG662

DOI：10.3969/j.issn.1004-132X.2025.04.012 开放科学（资源服务）标识码（OSID）：

Study on Low Wear Machining Method of High Volume Fraction SiCp/Al Composite Materials by ECM-mechanical Combined Machining Processes Method

HE Bin*ZHOU Xingyu LU Hongyu ZHANG Junfei DING Kai LI Qilin LEI Weining School of Mechanical Engineering，Jiangsu University of Technology，Changzhou，Jiangsu，213001

Abstract： To improve the problems of tool wear，poor surface quality and low machining efficiency of aluminum-based silicon carbide（SiCp/Al） composites with high volume fraction under conventional machining，an ECM-mechanical combined machining method was proposed，and the ECMmechanical combined machining experiments of 60% volume fraction SiCp/Al composites were carried out. The results show that SiC particles are exposed on the surfaces with the removal of aluminum matrix.There is a certain depth of transition zone between the surface of the workpiece and the matrix after ECM，the aluminum matrix in the transition zone is locally removed，and the binding force of SiC particles is reduced. When the diamond grinding rod is used for machining the transition zone，the aluminum matrix adhesion phenomenon is not observed，the diamond grinding rod has almost no wear，and the surface damages are obviously reduced. The machinability of high volume fraction SiCp/Al composites may be improved by ECM-mechanical machining processes.

Key words： aluminum-based silicon carbide composites（SiCp/Al）； electrochemical machining （ECM） ；tool wear;diamond grinding rod

0 引言

铝基碳化硅（SiCp/AI）复合材料以铝（AI）金属为基体，碳化硅（SiC）颗粒为增强相，具有强度高、耐磨性优、密度小、膨胀率低、导热性强等特性，广泛应用于航空航天、汽车工业、机械设备制造、电子电气、轻量化应用等领域[1-4]。然而，SiCp/Al复合材料优异的性能也导致其精密高效加工较为困难。

国内外学者对SiCp/A1复合材料加工方法进行了大量探究。关佳亮等5对中高体积分数（号 （40%.60% ） SiCp/Al 复合材料进行精密磨削加工研究，发现随着增强体SiC颗粒体积分数的增大，材料硬度变高，塑性变差，可加工性能降低，加工表面质量逐渐变差。GUO等[]对SiCp/Al复合材料高速磨削的材料去除机理进行研究，发现磨削速度较低时，铝基体发生严重的塑性变形并发生“涂抹\"现象，而SiC颗粒容易被拔出或推开而产生表面凹坑；高速磨削可以提高铝基体的硬度，抑制其塑性变形，从而降低表面粗糙度。向道辉等研究了高体积分数SiCp/A1复合材料磨削加工砂轮堵塞理论及原因，结果表明磨削

SiCp/Al复合材料时砂轮堵塞类型主要为黏着型堵塞，超声辅助可以改善砂轮的堵塞状况，延长砂轮的使用寿命。ZHANG等8对体积分数为20% 的 SiCp/Al 复合材料开展了铣削加工试验，发现在铣削过程中刀具表面发生粘刀而形成切屑瘤，切屑瘤的不断生成和消失使切削力不断变化，导致加工表面形成不规则的缺陷。LIU等通过对体积分数为 45% 的 SiCp/Al 复合材料进行微铣削加工，研究了不同进给率对铝基体与SiC颗粒去除机制的影响，发现较小的进给率会导致铝基质未完全去除，而较大的进给率会使SiC颗粒发生脆性断裂，导致表面缺陷的形成。……