Abrasive Electrical Discharge Machining (AEDM)

Modern industrial applications are increasing rapidly leading to the development of advanced materials such as metal matrix composites (MMCs). Machining of MMCs via conventional machining is often difficult. Thus, non-conventional machining methods like electric discharge machining (EDM), a thermal process, is being successfully employed for easy machining of MMCs. The EDMed top surface layer comprises of recast (white) layer which is generally removed by supplementary processes such as hand polishing, etching etc, leading to increased cost and time. Abrasive Electrical Discharge Machining (AEDM), is a hybrid process, in which free abrasive grains are mixed in the dielectric fluid. It is characterized by the mutual assistance of mechanical interaction (abrasion) and thermal interaction (electrical spark erosion). The present work presents the details of an experimental investigations carried out on 6061Al-Al2O3p-20% MMCs using the machining mechanisms with conventional EDM and AEDM with the addition of SiC abrasive powder in the dielectric and using copper tool electrode, so as to compare the benefits of hybrid process.