An Experimental Investigation for Optimization of WEDM Parameters During Machining of Fabricated Al/ZrO2(p)-MMC

This paper presents the fabrication process of Al/ZrO2(p)-metal matrix composite (MMC) by liquid stir casting technique. The paper also presents an experimental investigation of the machining characteristics and the effect of wire electrical discharge machining (WEDM) process parameters during machining of newly developed Al/ZrO2(p) MMC. Experiments have been carried out to investigate the effects of input parameters such as dielectric conductivity, pulse width, pulse off time, maximum feed rate, servo control mean reference voltage, pulse on time, wire feed rate, wire mechanical tension and dielectric injection pressure on performance measures like spark gap and material removal rate. The optimal setting of parameters has been determined through experiments planned, conducted and analyzed using Taguchi method. L-36-mixed orthogonal array (2(1) x 3(8)) has been selected to design the experiments. The significant process parameters have also been identified and their effects on performance measures have been studied in detail. The results obtained have been validated by conducting the confirmation experiments. Yield strength of the fabricated MMC has been found to be 88.3 MPa. The newly developed MMC can be machined effectively by WEDM and can be used in aerospace industries.