Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Abstract

The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiC g ) and black SiC (SiC b ) particles. The WEDM machining parameters, such as pulse on time (TON ), wire feed (WF) rate, and flushing pressure (FP) of the resultant stir cast AA6063/SiC b and AA6063/SiC g composites, were optimized using the Taguchi method with L9 orthogonal array to estimate the responses, such as surface roughness and metal removal rate. Further, through grey relational analysis, the finest parameters for WEDM of AA6063/SiC b and AA6063/SiC g composites were evaluated as TON = 50 μs, WF rate = 18 m/min, and FP = 3 MPa. With the optimum parameters obtained, conformational experiments were conducted, and the scanning electron microscopic images were recorded, along with the energy-dispersive X-ray (EDX) spectroscopic data of the worn surfaces and debris. From the EDX mapping images of the machined surface, it was evident that AA6063/SiC b displays a more polished surface than AA6063/SiC g . However, for applications requiring a high metal removal rate, AA6063/SiC g displays better results than AA6063/SiC b .

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO2 composite using response surface methodology

“…Numerous papers emphasize the improvement of the mechanical behavior of various materials, particularly aluminum alloys, in light of the dramatically increased industrial sector. Aluminium and its alloys are renowned for having low densities but high strengths that are on par with those of steel [4]. The use of aluminum composites is unavoidable in all engineering fields, including aviation and vehicle ventures, because of its higher quality-toweight ratio, resistance against corrosion and machinability [5].…”