Composites of high volume fraction are suitable in many applications because of their high strength-to-weight ratio, high hardness, and wear resistance. In this study, the influence of drilling parameters and volume fraction of aluminum oxide (Al2O3) on the material removal rate (MRR), surface finish, and overcut was investigated. Al-Al2O3 metal matrix composites were stirred cast with 10 %, 20 %, and 30 % of Al2O3 concentration and subsequently machined using computer numerical controlled drilling. Experiments based on Taguchi’s methodology were carried out with L9 orthogonal array. Analysis of variance and signal-to-noise ratio analysis revealed the ranking of the most influencing process parameters. High volume fraction reinforcement of Al2O3 shows an adverse effect on MRR, surface roughness, and overcut. The drilling of high volume fraction ceramic-reinforced composite shows a brittle fracture of hard particles leading to the generation of overcut on the top surface. An empirical relationship between the process parameters under consideration and response variables were established by using regression analysis. The mathematical equations obtained through this work can be extended to find out the optimum volume fraction of Al2O3 to have better MRR and accuracies. This work will be useful to the metalworking industry towards the development of products having excellent tribo-mechanical properties.
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