Influence of Input Parameters on Machining Performances of Slotted-Electrical Discharge Abrasive Grinding of Al/SiC/Gr Metal Matrix Composite

Abstract

Hybrid machining processes are advantageous for machining of difficult-to-machine hard and brittle materials due to their superior performance as compared to the constituent processes. The aim of the present study is to propose a novel hybrid machining called Slotted-Electrical Discharge Abrasive Grinding (S-EDAG), which is developed by comprising the Electro-Discharge Grinding (EDG) and Abrasive Grinding (AG) in such a way that both processes (EDG and AG) occur alternatively with application of the compound grinding wheel. The performance of the developed process has been experimentally tested on Aluminum-Silicon Carbide-Graphite (Al/SiC/Gr) composite. For effective studies of the process behaviors, the experiments were performed according to one parameter at a time technique. All the experiments were conducted on EDM machine by fastening a separate attachment of rotary unit on its vertical column. During experimentation, the effect of pulse current, pulse duration, pulse interval, wheel speed, and grit number have been studied on material removal rate (MRR) and average surface roughness (Ra). The experimental results show that high MRR with moderate Ra can be achieved at pulse current = 15 A, pulse duration = 120 µs, pulse interval = 90 µs, and wheel speed = 1,300 RPM.