Experimental Investigation on Machining of Recycled Aluminum Alloy Metal Matrix Composite in ECMM

Electrochemical micromachining (ECMM) is the well-known method for machining hard materials. In this research, the workpiece material is fabricated using stir-squeeze casting method with scrap aluminum alloy wheel (SAAW) and alumina as reinforcement. The fabricated material is machined using ECMM for micro-hole by the process of varying the factors, such as voltage, duty cycle, electrolyte concentration and stirrer speed with L18 orthogonal array (OA) experimental design. The factors are optimized using multi objective decision-making method namely Preference Ranking Organization METHod of Enrichment Evaluation (PROMETHEE-2). The best factor levels are 10 V, 90% duty cycle, 25 g/l, 140 rpm and based on analysis of variance (ANOVA) the stirrer rpm plays a dominant role in ECMM process by contributing 31.91%.