EFFECT OF ELECTROCHEMICAL MACHINING PROCESS PARAMETERS ON METAL MATRIX COMPOSITES COMPOSED OF SCRAP ALLOY WHEEL MATRIX

Electrochemical machining (ECM) is an anodic dissolution process in which cathode is a tool electrode and anode is a workpiece and these two electrodes are bridged by electrolyte. In this research scrap alloy wheel metal matrix composite (SAWMMC) was produced using stir casting setup, the Honda wheel was used as a base metal and 5% alumina (Al2O3) as a reinforcement. Using an ECM setup, the machinability studies on SAWMMC specimen was performed. The various input parameters such as voltage, duty cycle and electrolyte concentration on machining rate, overcut and surface corrosion factor were studied. The range of voltage significant for OC is7 to 8V. The MR increases gradually for 50% duty cycle and significant range of duty cycle is between 60 to 80%. The significant range of duty cycle for lesser OC is 60 to 80% and for lesser SCF is 70 to 90%.Hole surface quality is studied using FESEM images. The significant electrolyte concentration is 20 to 30gm/l for obtaining the higher MR. For electrolyte concentration of 15 to 30gm/l the OC decreases and increases to the maximum value for electrolyte concentration range of 30gm/l to 35gm/l. The significant range of electrolyte concentration for lower SCF is 25gm/l to 35gm/l. The hole analysis shows surface pitting/corrosion along the circumference and it is due to long exposure of stray current