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粉煤灰作为铝基复合材料的增强剂已得到越来越多的关注,其可以增强特定的性能,还可以减少制备成本。然而,铝基复合材料的加工性能较差限制了其发展。本研究采用复合铸造方法制备粉煤灰增强Al6061合金。X射线衍射分析表明铝基复合材料中只含有粉煤灰颗粒,不含其他金属间化合物。采用电火花切割评价所制备金属基复合材料的加工性能。采用不同的电火花切割工艺参数组合对材料去除率、电极磨损率、表面粗糙度等性能参数进行评价。采用响应曲面方法的中心复合设计对所需实验的数量进行优化,获得基于灰度的响应曲面方法,并用以预测电火花切割最佳工艺组合。采用基于灰度响应曲面方法预测得到的最佳工艺参数组合时,所得性能参数得到明显提高,电火花切割表面的3D轮廓图表明材料的表面质量和织构都得到提升。
As an enhancer of aluminum matrix composites, fly ash has gained more and more attention, which can enhance specific properties and reduce the manufacturing cost. However, poor processing properties of aluminum matrix composites limit their development. In this study, fly ash reinforced Al6061 alloy was prepared by the method of compound casting. X-ray diffraction analysis showed that the aluminum matrix composites contained only fly ash particles and no other intermetallic compounds. EDM was used to evaluate the machinability of the prepared metal matrix composites. Different EDM parameters were used to evaluate the material removal rate, electrode wear rate, surface roughness and other performance parameters. The central composite design using the response surface method is used to optimize the number of experiments required to obtain a greyscale response surface methodology and to predict the best combination of EDM techniques. The performance parameters obtained by the combination of the best process parameters predicted by the gray response surface method are obviously improved. The 3D contour of the EDM surface shows that the surface quality and texture of the material are improved.