Development and Experimental Study of Surface-Electrical Discharge Diamond Grinding of Al–10 wt%SiC Composite

Abstract

As silicon carbide possesses small fracture toughness, it is difficult to grind because it leads to cracking. Metal matrix composites can be machined using electrical discharge machining (EDM) but the process is slow. Electrical discharge diamond grinding (EDDG), which consists of diamond grinding and EDM with a rotating disk which enhanced material removal rate (MRR) and produce better surface finish. This paper describes the machining characteristic of Al–SiC composite using EDDG in surface grinding configuration which is called as surface-electrical discharge diamond grinding (S-EDDG). A chain of experiments were performed on S-EDDG set up by mounting newly self designed and fabricated set up on conventional die sinking EDM machine using the approach of one parameter-at-a-time concept. Surface roughness (Ra) and MRR are taken as output parameters as both are important outcome in the manufacturing process and they materialize a major division in the manufacturing system. The effects of current, wheel speed and depth of cut is analyzed on MRR and Ra. Finally, optimization have been done through weighted principal component analysis.