In the present research work effort has been made to study the tribological behavior of dual particle size (DPS) and triple particle size (TPS) of Al2O3 reinforced Al-MMCs (prepared by vacuum moulding process). The study started with selection of the component for industrial application. The study highlights the effect of reinforcement in form of DPS and TPS on mechanical and metallurgical properties of Al- Al2O3 MMCs. The input parameters of process are composition of MMC, vacuum moulding silica sand grain size, vacuum pressure and component volume. The study highlights the percentage contribution of different input parameters on micro hardness, dimensional accuracy and wear properties of Al- Al2O3 MMCs.