Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061A1 composite

This study investigates the feasibility and optimization of a rotary EDM wi th ball burnishing for inspecting the machinability of Al2O3/6061Al composi te using the Taguchi method. Three ZrO2 balls attached as additional compon ents behind the electrode tool offer immediate burnishing following EDM. Th ree observed values (machining rate, surface roughness and improvement of s urface roughness) are adopted to verify the optimization of the machining t echnique. In addition, six independent parameters are chosen as variables f or evaluating the Taguchi method; these variables are categorized into two groups: (1) electrical parameters, i.e, peak current, pulse duration and no n-load voltage; and (2) non-electrical parameters, i.e, flushing pressure o f dielectric, rotational speed of electrode and residual height of hump. Ex perimental results indicated a feasible technique for applying rotary EDM w ith ball burnishing in machining the Al2O3/6061 composite. Optimization of this technique is also discussed. (C) 2000 Elsevier Science Ltd. All rights reserved.