Original Article

Enhancing machining performance of AlSi10Mg composites using EDM: a Taguchi–RSM–random forest approach

¹ Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Namakkal District, Tamilnadu ‐ 637 503, India
² Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh, 791109, India

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Received: 27 September 2025
Accepted: 7 December 2025

Abstract

Electrical Discharge Machining (EDM) technology is one of the most important non‐traditional machining processes of advanced conductive ceramic composites, which are exceptionally difficult to machine by conventional methods. This paper examines the machinability of the AlSi10Mg composites by EDM with three electrode materials (copper (Cu), brass (Br), and tungsten carbide (WC)) at different process conditions. The key performance indicators analyzed were Material Removal Rate (MRR), Tool Wear Rate (TWR), Surface Roughness (SR), and geometric tolerances, including circularity, cylindricity, perpendicularity, run‐out, and taper angle. The experimental design was determined by an L₁₈ Taguchi orthogonal array, and high‐end metrology instruments such as CMM, VMM, and surface profilometers were used to assure the correctness of the output measurements. Response Surface Methodology (RSM) came up with second‐order regression formulae that were highly predictive in the sense that they yielded a high predictive efficiency (R² = above 85 percent) and offered a validation of the model by Random Forest Regression, which revealed that there was a very high correlation between experimental and predicted results. Microstructural and surface integrity were observed using Scanning Electron Microscopy (SEM) and Energy Dispersive X‐ray Spectroscopy (EDS), and the results revealed that micro‐craters, re‐solidified layers, and a small amount of thermal damage can occur in ideal conditions. Copper electrodes were known to be the most effective in MRR, and tungsten carbide was the most effective in wear resistance. Overall, the research may provide a good framework on the enhancement of the functionality of EDM of AlSi10Mg composites by relating the process parameters, electrode material, and surface integrity. These optimizations are directly linked to shorter machining time, extended tool life, and less electrode usage so that they result in less production cost and higher dimensional accuracy. These measurable gains can be particularly important to aerospace, automotive, and precision tooling industries, where surface finish and geometric integrity are critical concerns with regard to component reliability.