Electric discharge sawing of hybrid metal matrix composites

Electric discharge sawing process is a novel process for the enrichment of capabilities of electric discharge machining. The process has been developed to cut materials at greater depths where the effect of flushing becomes ineffective. During electric discharge machining at greater depths, ineffective flushing prevents debris and carbon particles from leaving the machining zone and gets accumulated in the sparking zone reducing the spark efficiency. This reduces material removal rate and causes arcing or short circuiting which may damage the workpiece and/or tool surface. In the present experimental endeavor, a new process capable of preventing debris accumulation during machining of slots at large depth and subsequently increasing material removal rate has been developed. In the process, a reciprocating motion is given to the tool blade similar to the power hacksaw blade. An experimental investigation based on central composite design has been conducted on hybrid metal matrix composite to evaluate the effect of input parameters on material removal rate and tool wear rate. It has been found that the electric discharge sawing process is quick and effective as compared to the conventional cutting process.