Machining of aluminium-based composites by wire EDM: a review

This review provides a clear understanding of the wire electrical discharge machining (WEDM), a highly sophisticated thermo-electric machining technique that may create intricate patterns that are challenging to manufacture using traditional machining techniques. Nowadays, sophisticated machining processes are replacing traditional machining techniques due to the extraordinary strength, toughness, and hardness of advanced materials like composites. WEDM is an excellent choice for manufacturing micro-scale components with the highest dimensional precision and surface finish qualities. This beneficial technique for the WEDM operation is based on the standard EDM sparking phenomena and uses the regularly utilised non-contact material removal method. We have also explored the potential future development of these machining techniques. Optimising the parameters for the processes would help increase the output of various sectors. The examination of unconventional machining methods using different optimisation techniques is presented in this article. Numerous optimisation techniques were investigated in this study, such as Taguchi's, analysis of variances, genetic simulated annealing, artificial neural networks, particle swarm optimisation, response surface approach, and artificial bee colony method. The study also looks at the feasibility of various control strategies to reach optimal machining parameters, emphasising adaptive monitoring and control of the operation.Abbreviations: Al-MMC: Aluminum metal matrix composites; ANN: Artificial neural network; ANOVA: Analysis of variance; BBD: Box-Behnken’s design; GRA: Grey relation analysis; Ip: Peak current; MRR: Material removal rate; RSM: Response surface methodology; SG: Spark gap; SR: Surface roughness, Ra; SV: Spark gap voltage; Ton: Pulse on time; Toff: Pulse off time; TOPSIS: Technique for order of preference by similarity to ideal solution; WEDM: Wire electrical discharge machining; WF: Wire feed rate; WT: Wire tension