Hypereutectic aluminium-silicon (Al-Si) alloys are used in
automobile components because of high wear resistance and
good strength properties. Because of their low density, high
wear resistance and high strength at elevated temperature, such
alloys are used for engine blocks, air compressor cylinders and
VTR cylinder heads [1]. These alloys generally contains 16–
18% of silicon and have a wear resistance better by about
35% than that of eutectic Al-Si alloys containing 12% of
silicon. However, the hard particles present in hypereutectic
alloys accelerate the wear of cutting tools during machining
[2]. This restricts the use of hypereutectic Al-Si alloys. Miller
[3] has observed wear phenomena during the machining of Al-
Si alloy with a tungsten-carbide tool and a polycrystalline
diamond tool. Wilson [4] studied the machining economics of
cast aluminium alloys with compax blank tools. Advances in
hypereutectic Al-Si alloy machining have been suggested by
the finding that single-crystal diamond tools produce a good
mirror-like surface for Si extraction [5]. The application of
this in industry should be based on an analysis of the economics
and applicability. The final target of product manufacturing