Some investigations into wire electro-discharge machining performance of Al/SiC<SUB align=right>p composites

Abstract

Non-traditional process like Wire Electro-Discharge Machining (WEDM) is found to show a promise for machining Metal Matrix Composites (MMCs). In the present study, the effect of various control parameters such as pulse on-time, off-time, ignition pulse current, wire speed, wire tension and flushing pressure on cutting speed and surface finish in WEDM of Al/SiCp has been investigated by using Taguchi methods. Mathematical models relating the machining performance and machining parameters have been formulated. Optimal settings for each performance measure have also been obtained. A comparative study on unreinforced alloy revealed the effect of reinforcement on the machining process. It was found that the cutting speed for unreinforced alloy was higher compared to MMC. But surface finish in MMCs was superior compared to the unreinforced alloy. Wire breakage was found to pose limitations on the cutting speed of MMC.