Development of a reversible motion wire-electrochemical spark cutting (RM-WECSC) setup for profile cutting with high cutting rate in a microcut width of Al₂O₃ ceramic epoxy nanocomposite

An indigenous hybrid machining process, i.e., a wire electrochemical spark cutting setup, was developed with high reversible wire motion (11–19.8 m/min). It is suitable for cutting/machining, especially for nonconductive advanced engineering materials with high cutting rate and uniform microcut width. Cutting was performed above the electrolyte surface and a self-developed electrolyte flow was observed on both sides of the microcut width. Consequently, fused materials were washed out from the cutting/sparking zone. The cutting rate and microcut width of an Al₂O₃ ceramic epoxy nanocomposite was analyzed on the basis of input parameters, such as electrolyte concentration, pulsed DC applied voltage, pulse on-off time, and reversible wire velocity. The cutting rate was 322.11–1445.95 µm/min, and the microcut width ranged from 183.57 µm to 550 µm. Thermal cracks, heat-affected zones, and recast layers were not found on the cut surface and were analyzed using a field emission scanning electron microscope. A fluorescence microscope was used to measure curve cut length and microcut width.