The Effect of Different Magnet Intensities on EDM Turning of Al7075/Zro₂ MMCs: A Comprehensive Investigation

The study explores the fabrication of an aluminum-based metal matrix composite (Al7075/ZrO₂ MMC) and its machining using an electrical discharge turning setup with magnetic field (MF) assistance. The study aims to evaluate the impact of varying magnetic field intensities on key machining parameters, including material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness (Ra), while keeping rotational speed (N), gap current (Ig), and pulse-on-time (Ton) constant. Results indicate substantial increment in MRR (38.14%) and TWR (44.89%) with increasing magnetic field intensity. Additionally, overcut decreases by 38.81%, and surface roughness diminishes by 38.11% under higher magnetic field intensity conditions. Scanning electron microscopy (SEM) analysis reveals minimized recast layer (RLT) and debris on the machined surface at higher magnetic field intensities, suggesting improved surface characteristics. This research contributes to understanding the beneficial effects of magnetic field assistance on the machining performance of aluminum-based metal matrix composites, particularly highlighting its potential for enhancing productivity and surface quality in various industrial applications such as aerospace, marine, and automobile sectors.