Selection of Optimum Parameters in Non Conventional Machining of Metal Matrix Composite

Aluminium metal matrix composites (AMMCs) are now gaining their usage in aerospace and automotive industries. Because of their inherent nature, difficult to machine, they find very little applications in other sectors. Even non traditional processes like Laser Jet Machining and Electro Discharge Machining result in significant sub surface damage to the work. In this paper, an attempt is made to machine the A356/SiCp composite work material using Electro Chemical Machining process. Silicon carbide with an average particle size of 40 microns is tried in three different proportions, namely 5%, 10% and 15% by weight. Taguchi’s L27 orthogonal array is chosen to design the experiments and 54 trials are conducted to study the effect of various parameters like applied voltage, electrolyte concentration, feed rate and percentage reinforcement on maximizing the material removal rate. ANOVA results have shown that all the four selected factors are significant and from the S/N graph the optimum level of each factor is chosen. A mathematical model is also developed using the regression method. Confirmation experiment is conducted and found that the data obtained have close match with the data predicted using the model.