Random Forest-Based Wire Cut Electro-Discharge Machining of Physella Acuta Shell Particles Reinforced AA1050 Composite with Microstructural Analysis

The high strength and light weight of aluminum matrix composites have made them the material of choice for many engineering applications. Snail shells and other bio-reinforcements offer a potential substitute for conventional ceramic reinforcements. However, the inherent difficulty in machining Aluminum Matrix Composites (AMCs) stems from the presence of reinforcing particles. This study investigates the machinability of aluminum matrix composites (AMCs) reinforced with Physella Acuta snail shell (PAS) particles using Wire Electrical Discharge Machining (WEDM) with a zinc-coated brass wire electrode. The primary objective is to determine how various input elements affect process conditions to achieve the desired surface quality. In order to do this, the Random Decision Forest approach was employed. Scanning Electron Microscopy (SEM) evaluation revealed the presence of microvoids, surface defects, deep craters, and crack propagation. It was found that the random forest method had an F1-score of 0.94, a recall of 0.96, and a precision of 0.97. The optimized parameters yielded an MRR of 0.5 mm3/min, SR of 2.14 µm, and EWR of 0.017.