Machining of Interpenetrating Phase Alumina/Aluminium Composite by Electrical Discharge Technique

Factors influencing the behaviour of alumina/aluminium interpenetrating phase composite during wire-cut electrical discharge machining (WEDM) are studied. Machining performance in terms of material removal rate (mm1.mm−1) and surface roughness (Ra) were compared under different machining conditions. Results show that the machining process affects the surface quality of the machined composite. Under the conditions of the present study, the cutting rate and surface roughness are inter-dependent and vary between 5 and 8 mm3.min−1 and 3 and ~4 μm, respectively. WEDM cutting gives rise to the formation of a heat-affected surface layer containing pores and a few cracks. The results are analyzed using the prevailing concepts of electro-discharge machining.