Non-conventional machining of particle reinforced metal matrix composites

Particle reinforced metal matrix composites (PRMMCs) have proved to be extremely difficult to machine using conventional manufacturing processes due to heavy tool wear caused by the presence of the hard ceramic reinforcement. This paper presents details of an investigation into the machinability of silicon carbide particle reinforced aluminium alloy matrix composites using non-conventional machining processes such as electro discharge machining (EDM) and laser cutting. The different removal mechanisms of the different processes when machining the composite were investigated. The surface condition and sub-surface damage of the material for the different machining processes have been examined and compared. It appears that both EDM and laser are suitable processes for machining PRMMCs, laser offers significant advantages in terms of removal rate. EDM however induce less thermal damage than that was observed using the laser.