Methodology for Surface Reconstruction and Prediction Based on the Electrical Discharge Machining Removal Mechanism of C-UHTC Materials.

C-UHTC is an ideal aerospace material because of its exceptional properties, but its machinability is facing great challenges. Electrical discharge machining (EDM) offers a potential solution, but its removal mechanism remains unclear, lacking reliable prediction tools to guide the actual production. This paper deeply explores the EDM removal mechanism of C-ZrB-SiC through single-pulse experiments, high-speed camera observations, and thermal-fluid coupling simulations, revealing key processes like heat transfer, phase transformation, molten pool dynamics, crater formation, and reinforcing phase effects. And the prediction of single-pulse removal with different parameters is also realized. Based on experimental and simulation results, a random continuous discharge model is developed, which deeply studies the dynamic erosion process, reconstructs EDM surfaces, and accurately predicts surface roughness. Furthermore, the thickness of the recast layer can be predicted based on the equivalent temperature method. Undoubtedly, this model provides an ideal approach for efficient production.