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<p>Powder mixed electrical discharge machining (PMEDM) is promising for machining silicon carbide reinforced aluminum (SiC/Al) composites but requires deeper mechanism understanding and parameter optimization. This study integrates thermodynamic simulation, experimental analysis, and multi-objective optimization to address this. First, a transient thermodynamic model is developed to simulate the single-discharge process, revealing that increasing the peak current significantly expands the heat-affected zone and peak temperature, thereby increasing the crater volume. Subsequently, the coupled effect of electrode polarity and SiC volume fraction is experimentally deciphered, showing that positive polarity maximizes MRR (98.05&#xa0;mm<sup>3</sup>/min at 15&#xa0;vol.% SiC) while negative polarity yields the finest surface finish (Ra 1.43&#xa0;μm at 10&#xa0;vol.% SiC). Finally, a Taguchi L<sub>16</sub> orthogonal design with Grey Relational Analysis is employed to optimize four key parameters. Analysis of Variance on the grey relational grade statistically confirms that powder concentration and peak current are the dominant factors. The derived optimal parameter set (pulse duration: 25&#xa0;μs, pulse interval: 125&#xa0;μs, peak current: 16 A, powder concentration: 10&#xa0;g/L) was validated, achieving a processing time of 865&#xa0;s, an MRR of 79.744&#xa0;mm<sup>3</sup>/min, a relative wear ratio of 0.412%, and a surface roughness of Ra 1.482&#xa0;μm. These results correspond to simultaneous improvements of at least 31% across all performance metrics compared to the pre-optimization condition. This work provides not only an optimized process window but also deepened mechanistic insights for the high-performance PMEDM of SiC/Al composites.</p> Graphical abstract <p></p>

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Parametric investigation and optimization of powder mixed EDM SiC/Al composites through simulations and experiments

  • 期刊论文

  • 发表日期：

    2026年4月13日

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  • Tong Cao,
  • Yiming Peng,
  • Xinyu Zhang,
  • Minghang Lv,
  • Lin Tang

摘要

Powder mixed electrical discharge machining (PMEDM) is promising for machining silicon carbide reinforced aluminum (SiC/Al) composites but requires deeper mechanism understanding and parameter optimization. This study integrates thermodynamic simulation, experimental analysis, and multi-objective optimization to address this. First, a transient thermodynamic model is developed to simulate the single-discharge process, revealing that increasing the peak current significantly expands the heat-affected zone and peak temperature, thereby increasing the crater volume. Subsequently, the coupled effect of electrode polarity and SiC volume fraction is experimentally deciphered, showing that positive polarity maximizes MRR (98.05 mm3/min at 15 vol.% SiC) while negative polarity yields the finest surface finish (Ra 1.43 μm at 10 vol.% SiC). Finally, a Taguchi L16 orthogonal design with Grey Relational Analysis is employed to optimize four key parameters. Analysis of Variance on the grey relational grade statistically confirms that powder concentration and peak current are the dominant factors. The derived optimal parameter set (pulse duration: 25 μs, pulse interval: 125 μs, peak current: 16 A, powder concentration: 10 g/L) was validated, achieving a processing time of 865 s, an MRR of 79.744 mm3/min, a relative wear ratio of 0.412%, and a surface roughness of Ra 1.482 μm. These results correspond to simultaneous improvements of at least 31% across all performance metrics compared to the pre-optimization condition. This work provides not only an optimized process window but also deepened mechanistic insights for the high-performance PMEDM of SiC/Al composites.

Graphical abstract