A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Abstract

Among the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiC p /Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiC p /Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiC p /Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiC p /Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiC p /Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications.

Experimental Research on the Cutting of Metal Materials by Electrical Discharge Machining with Contact Breaking with Metal Band as Transfer Object

“…The cutting of high steel alloys by electrical discharge machining with contact breaking (EDMCB) with electrode-tool—the metal band—represents one of the modern technological procedures of the non-conventional processing of some high steels alloy (hard and extra hard) categories, under the economic conditions of optimal efficiency [ 32 , 33 ]. The experimental research regarding the cutting process has emphasized, in particular, the technological aspects specific to the cutting (semi-fabricated of high steels alloy) through EDMCB, with Transfer Object (TO)—metallic band.…”

“…The dependency of the cutting time (t t ) to the feeding rate (v a ) of the processing object and the working current (I) is presented in Figure 16. • Thus, the cutting time (t t ) reaches the optimal values (30)(31)(32) [s] when the input parameters within the working cycle have been set for the following values: • The dependency of the cutting time (t t ) to the relative speed (v r ) of the electrode-tool and the working current (I).…”

“…The cutting time (t t ) reaches the optimal values (30)(31)(32) [s] when the input parameters are set for the following values: Each of the input parameters determines a certain influence on the cutting time (t t ).…”

“…Specific researches are presented in the literature where a redistribution of specific energies is observed in the processing of different types of materials that include aluminum alloys and sandwich panels [ 28 , 29 , 30 ]. Specific studies and research have been considered, which include issues of reliability and maintenance of material sampling processes using modern numerical simulations [ 31 , 32 , 33 ].…”

Effects of Electrical Parameters during Non conventional Machining of Al/Sic Metal Matrix Composites by Electrical Discharge Machine

“…the composite electrodes obtained a higher MRR than Cu metal electrodes; the recast layer was thinner and fewer cracks were present on the machined surface [4]. The regression models [5] and Taguchi methods [6] are used for modeling and analyzing the influence of process Variables computer simulation of EDM machining with the side and face of the electrodes is developed [7,10].…”