Abstract
Two types of permanent mould materials, spheroidal graphite (SG) cast iron and Al-Si alloy with various compositions, were selected to study the effect of heterogeneous second phase on material removal rate (MRR) by the electro-discharge machining (EDM) process. Fe-Si alloy and Al-1wt%Si alloy with a mainly single-phase structure were also prepared for comparison.Experimental results indicated that the amount and morphology of second phase particles significantly influence the material removal rate (MMR). This is closely related to ridge density and discharge density during the EDM process.The EDMed surface of the specimens had a continuously ridged appearance and the ridge density increases with higher amount of second phase. Worthy of notice is that the graphite particles are embedded in the troughs on the EDMed surface of SG cast iron, while the eutectic silicon particles are located on the ridge region in the case of Al-Si alloys.
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