Table of Contents

ABSTRACT

Non-traditional process like wire electro-discharge machining (WEDM) is found to show a promise for machining metal matrix composites (MMCs). In the present study, the effect of various control parameters such as pulse on-time, off-time, ignition pulse current, voltage, servo reference mean voltage, and percentage of ceramic reinforcement in the metal matrix composite on cutting speed and kerf width in WEDM of Al/SiCp has been investigated by using Taguchi methods. Mathematical models relating the machining performance and machining parameters have been formulated. Optimal settings for each performance measure have also been obtained. This study revealed the effect of reinforcement on the machining process. It was found that the cutting speed for 10 % particle reinforced alloy was higher compared to other two MMCs with 20% and 30% ceramic particle reinforcements. But kerf width in higher reinforcement MMCs was superior compared to the 10% MMC. Wire breakage was found to pose limitations on the cutting speed of MMC. Significant banding was observed on the machined surfaces.

Keywords: Metal matrix composites, MMCs, Wire electro-discharge machining, WEDM, Taguchi methods.