Abstract : Diamond wire sawing is one of the most widely used methods of cutting Al 2O 3 ceramic because it has good machining accuracy and causes less surface damage. However, its material removal rate (MRR) needs to be improved with the increasing demand for Al 2O 3 ceramic parts. In this paper, spark discharges are generated around the diamond wire based on the electrochemical discharge machining (ECDM) process. An oil film-assisted ECDM process is applied to solve the difficulty of generating spark discharges when the thickness of the workpiece exceeds 5.0 mm due to the difficulty of forming a hydrogen gas film. Experimental results show that the combination of oil film-assisted ECDM and diamond wire sawing improved the MRR of Al 2O 3 ceramic. Oil film-assisted ECDM may improve the surface quality of machined parts and reduce the wear on diamond wire. Therefore, this research focuses on the surface quality of Al 2O 3 ceramic and tool wear in diamond wire sawing combined with oil film-assisted ECDM. Surface roughness and topography, recast layer, and elements of the machined surface are analyzed. The tool wear is studied using SEM images of diamond wire. The results provide a valuable basis for application of diamond wire sawing combined with oil film-assisted ECDM. Keywords: surface quality; tool wear; oil film-assisted ECDM; diamond wire sawing; Al2O3 ceramic
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