Modeling and optimization of process parameters for electric discharge machining of Al/Fe/SiC/MoS2 hybrid composites

Machining metal matrix composites with conventional machining raises challenges due to the incorporation of hard particles in a softer matrix, resulting in lower tool life and surface finish. Adopting non-conventional methods such as Electric Discharge Machining (EDM) eases the machinability of such materials. This study evaluates the effect of EDM process parameters and composition, i.e., reinforcement weight fraction, on Al/Fe/SiC/MoS2 hybrid metal matrix composites. The impact of composition and machine variables, such as pulse-on time (TON), peak current (I), and duty cycle, are systematically studied to analyze material removal rate (MRR) and surface roughness (SR). The experiments were conducted using the Central Composite Design of Response Surface Methodology. ANOVA was used to emphasize the crucial role of process parameters in influencing MRR and Sr The study identifies optimal parameter combinations at a peak current of 9 A, a pulse on time of 100 mu s, a duty cycle of 0.7909, and a 15% composition of reinforcements in pure aluminum, enhancing overall EDM process responses.