Tunneling machining characteristics of aluminum matrix composite using a wire electrode discharge machining (WEDM) process

Abstract

This thesis presents the machining of Aluminium Matrix Composites (AMCs) using wire electro-discharge machining (WEDM) with brass wire diameter of 0.25mm used as the tool electrode. The main purpose of this study was to investigate the influenced of various parameters involved in WEDM on machining characteristics, namely, material removal rate (MRR) and surface roughness (Ra) after undergone WEDM process. The Full Factorial Design of Experiment approach with two level was used to formulate the experimental layout, to analyze the effect of each parameter on the machining characteristics and to predict the optimal setting for each WEDM parameters such as pulse time-on(TON), peak current(IP) and supply voltage(V). Confirmation test were also conducted for the optimum conditions for each machining characteristics in order to verify and compare the results from the theoretical prediction using Regression Analysis on Minitab’s software. In this investigation, the machining operation was performed on 15 vol.% Al2O3p AMCs that produced using Powder Metallurgy with dimension 10mm×3mm×4mm. It performed using a Sodick linear motor WEDM series AQ327L. Meanwhile, for the measurement equipments, Mitutoyo CS-3100 tester was used to measure Ra.The images sample was scanned by using JSM 6460LA Scanning Electron Microscope (SEM).