Experimental investigations on electro erosion milling of Al-SiC metal-matrix composite

Abstract

ABSTRACT This article demonstrates the electro erosion milling process in Al-SiC metal matrix composites. Material Erosion Rate (MER) and Tool Erosion Rate (TER) are measured which depict the productivity aspect of the process. Depth and width of the slots, surface roughness (Ra) is used to indicate the geometrical accuracy. Maximum MER (0.1097 mm3/min) is obtained at 5A. Maximum TER (0.65 µm/min) is obtained at 2.15A. Minimum Ra (2.13 µm) is obtained at 2.15A. Maximum MER (0.1194 mm3/min) is obtained at 100µs. Lowest TER (0.73µm/min) is obtained at 10µs. Lowest Ra (7.66µm) is obtained at Ton of 100µs. Jaya algorithm is used to optimize and create Pareto front from which the results are extracted and reported. Material removal mechanism has been detailed which includes melting / evaporating of matrix material, electrochemical dislodging of SiC grains. Better surfaces have crater diameters ranging from 40–50µm and the bigger craters are in the range of 100–150µm.