Enhanced Machinability of SiCp/Al Composites with High Volume Fraction Using Photocatalytic-Assisted Electrochemical Drilling

Silicon carbide particle reinforced aluminum matrix composites SiCp/Al are widely applied in various fields owing to their targeted advantages. However, particle size and volume fraction present significant machining challenges that impact the machining of SiCp/Al composites. Electrochemical machining (ECM) offers significant surface integrity and high machining quality. A photocatalytic process is incorporated into electrochemical drilling (ECD) to solve the machining challenges posed by SiC particles. Through photocatalytic-assisted electrochemical drilling (PAECD), the material removal effect of 45% and 65% volume fraction SiCp/Al composites is more pronounced at different feeding displacements, which can improve the machining accuracy, surface quality and machining efficiency. Experimental results demonstrate that PAECD achieves a higher material removal rate (MRR), smaller taper angle, and lower sidewall surface roughness Ra value. Meanwhile, the reduction in tool wear and the increase in MRR optimize machining efficiency, thereby enhancing the machinability of SiCp/Al composites with high volume fraction.