STUDIES ON MACHINING OF METAL MATRIX COMPOSITES USING ELECTROCHEMICAL MACHINE

Electrochemical machining (ECM) is a promising method for fabrication of components made of difficult-to-cut materials, such as metal matrix composites (MMC) and nickel-based alloys. ECM is applied in various industries, including the aerospace and automobiles, especially as a finishing process. Research on fabrication of holes, three-dimensional structures, and cross holes through ECM is envisioned and performed. In this research, ECM is used to fabricate holes on MMCs, casted with scrap alloy wheel reinforced with 5% alumina (Al<sub>2</sub>O<sub>3</sub>). Input parameters, such as voltage, electrolyte concentration, duty cycle, and stirrer speed, vary on machining speed, overcut, and conicity factors. The conicity factor was found to increase linearly from 100 to 200 rpm stirrer speed. The conicity factor increased drastically from 5 to 7 V and increased less linearly at a voltage range of 7 to 10 V. The increase in duty cycle increased the overcut and conicity factor. The optical microscope images of the hole show the contribution of the stirrer on hole circularity.