Opportunities and challenges in machining of aluminium metal matrix composites using electrical discharge machining

Abstract

The machining of aluminium metal matrix composites (aluminium MMCs) presents a dynamic landscape of opportunities and challenges, with electrical discharge machining (EDM) emerging as a promising technique. This review article systematically navigates the intricate interplay between AMMCs’ unique characteristics and the EDM process. Through a comprehensive analysis of existing literature, we uncover the underlying mechanisms that govern the machining dynamics of AMMCs, exploring their compositional variations, reinforcement distribution and thermal properties. The article delves into the opportunities offered by EDM, such as precision machining of intricate geometries, inherent thermal control and the ability to navigate the varying hardness levels in AMMCs. Furthermore, the review addresses the challenges that arise, including electrode wear, surface integrity preservation and the influence of reinforcement particles on material removal rates. The authors highlight the role of parameter optimisation in achieving desirable machining outcomes, underlining the need to strike a balance between material removal efficiency and surface finish quality. Additionally, environmental considerations in EDM of AMMCs are discussed, emphasising sustainable machining strategies in line with contemporary ecological concerns. As the field of advanced materials and manufacturing continues to evolve, this review article provides valuable insights for researchers, engineers and industries seeking to harness the potential of EDM in machining AMMCs. By navigating the intricate landscape of opportunities and challenges, this article contributes to a holistic understanding of the nuanced relationship between EDM and AMMCs, laying the foundation for future advancements in precision machining of these composite materials.