Some studies into wire electro-discharge machining of alumina particulate-reinforced aluminum matrix composites

Non-traditional process like wire electro-discharge machining is found to show a promise for machining metal matrix composites. However, the machining information for the difficult-to-machine particle-reinforced material is inadequate. This paper is focused on experimental investigation to examine the effect of electrical as well as non-electrical machining parameters on performance in wire electro-discharge machining of metal matrix composites (Al/Al₂O₃p). Taguchi orthogonal array was used to study the effect of combination of reinforcement, current, pulse on-time, off-time, servo reference voltage, maximum feed speed, wire speed, flushing pressure and wire tension on cutting speed, surface finish, and kerf width. Reinforcement percentage, current, and on-time was found to have significant effect on cutting rate, surface finish, and kerf width. The optimum machining parameter combinations were obtained for surface finish, cutting speed, and kerf width separately. Wire breakages were found to pose limitations on the cutting speed in machining of these materials. Wire shifting was found to deteriorate the machined surfaces.