Electro-discharge drilling of metal matrix composites

Abstract Currently, industrialists are seeking advanced applications for metal matrix composites (MMCs) because of their superior mechanical properties. The use of MMCs provides better strength and impact toughness to products as well as lowers the material cost and weight. Researchers are making efforts to introduce such materials, which are economical in every aspect (e.g., cost, machinability, applicability, etc.), from an industrial point of view. In this study, we examined machining aspects of an aluminum-based hybrid MMC (Al6063/SiC/Al 2 O 3 /Gr) using electro-discharge drilling (EDD) with a copper tool electrode. The objective of this chapter is to investigate experimentally the process parameters of the EDD process based on the one-factor-at-a-time (OFAT) approach. As such, we measured the effect of process parameters (discharge current, duty factor, pulse off time, gap voltage, tool speed, and flushing pressure) on output responses (tool wear rate [TWR] and surface roughness [SR]) with the goal of minimizing TWR and SR during the EDD hole-making process.