Investigation of Surface Properties of Al–SiC Composites in Hybrid Electrical Discharge Machining

Abstract

In this research study, hybrid AJEDM (abrasive jet-assisted EDM) had been employed on the aluminum–silicon carbide composite (Al–SiC) material with an aim to attain high surface finish along with the higher material removal rate and lower tool wear rate. SiC abrasive particulates mixed EDM oil was used as a dielectric medium for flushing from the center of the tool electrode. The input parameters, for instance current, pulse-on/off, dielectric medium, and tool hole diameter were considered. It has been observed in the research work that MRR is significantly affected by the machining parameters such as peak current, pulse-on/off as well as type of flushing conditions and MRR enhanced significantly with the increase in spark energy at lower pulse-off time whereas the flushing by dielectric mixed with SiC particulates lead to sharp reduction in MRR. However, surface finish improved steeply in SiC-assisted dielectric flushing conditions. But surprisingly, the tool erosion rate drastically reduced with SiC-assisted flushing of dielectric fluid along with thinner recast layer. The selected parameters like current, hole diameter, and pulse-on/off time showed insignificant effect on the TER and SR. Furthermore, the results were advocated with various SEM and EDS images.