ABSTRACT Metal matrix composites (MMC’s) with their exceptional properties are gaining importance in many industries (i.e., automobile, structural, aerospace, etc.). The secondary processing of MMC’s, like machining, is challenging and sometimes infeasible by conventional machining processes. The present study reports development and investigation on a new non-conventional hybrid machining process named near-dry wire electrochemical discharge machining (ND-WECDM). The investigation involved understanding the material removal mechanism of developed ND-WECDM for machining of Al6063/SiC/10p MMC. A detailed experimental investigation was planned and conducted using Taguchi’s L18 mixed-level design. The influences of input parameters (i.e., pulse on-time, applied voltage, mist flow rate, wire feed rate, and pulse off-time) were analyzed on the slit width (SW) and slit depth (SD) as the performance characteristics. The significant parameters affecting the ND-WECDM process were identified by applying the ANOVA. The SW and SD were most affected by the applied voltage and pulse on-time, respectively. In the ND-WECDM process, material removal is due to electric discharge (ED), electrochemical dissolution (ECD), and thermal spalling (TS). ND-WECDM process is found competent to develop micro features on Al6063/SiC/10p MMC.

中文翻译：

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Al6063/SiC/10p MMC的近干线ECDM

摘要 金属基复合材料 (MMC) 以其卓越的性能在许多行业（即汽车、结构、航空航天等）中越来越重要。MMC 的二次加工，如机加工，是具有挑战性的，有时通过传统的加工工艺是不可行的。本研究报告了一种名为近干线电化学放电加工 (ND-WECDM) 的新型非常规混合加工工艺的开发和研究。调查包括了解用于加工 Al6063/SiC/10p MMC 的已开发 ND-WECDM 的材料去除机制。使用田口的 L18 混合级设计计划并进行了详细的实验研究。输入参数的影响（即脉冲导通时间、施加电压、雾流率、送丝率、和脉冲关断时间）作为性能特征对狭缝宽度（SW）和狭缝深度（SD）进行了分析。通过应用方差分析确定了影响 ND-WECDM 过程的重要参数。SW 和 SD 分别受施加的电压和脉冲导通时间的影响最大。在 ND-WECDM 工艺中，材料去除是由于放电 (ED)、电化学溶解 (ECD) 和热剥落 (TS)。发现 ND-WECDM 工艺能够在 Al6063/SiC/10p MMC 上开发微特征。电化学溶解 (ECD) 和热剥落 (TS)。发现 ND-WECDM 工艺能够在 Al6063/SiC/10p MMC 上开发微特征。电化学溶解 (ECD) 和热剥落 (TS)。发现 ND-WECDM 工艺能够在 Al6063/SiC/10p MMC 上开发微特征。