Experimental Investigation of Tool Wear Rate (TWR) During the EDM of Hybrid Aluminum Metal Matrix Composite Reinforced with SiCp and Grp

The EDM is the suitable and effective machining process for machining the hybrid aluminum metal matrix composites. This paper investigates the significant effect of machining parameters (pulse-on time, pulse-off time, voltage, and current) on the response variable tool wear rate (TWR). In this experimental work, three different aluminum metal matrix composite (Al MMC) samples were fabricated with distinct compositions of reinforcements by the stir casting process. The SiCp and Grp were used as reinforcements. Machining was done through EDM, with three different electrodes materials (steel-304, brass, and copper) with O12 mm each. The design matrix and mathematical models were developed by RSM using the Design-Expert 9.0.6 software. To check the signification of model, the ANOVA technique was used. The SEM and EDS were used to study the surface characteristics and elements analysis, respectively, of the machined electrodes. It was inspected that the cracks and craters are produced in all the fabricated samples. In this study, it was also examined that the Al MMC-1 (10% SiCp and 3% Grp) is the best fabricated composite as compared to the other two composites in terms of wear resistance and hardness.