Modeling and prediction of die sinking EDM process parameters for A6061/6%B4C metal matrix composite material

The aluminium metal matrix composites (AMMCs) are used in aerospace applications due to their excellent mechanical properties. The die-sinking electrical discharge machining (EDM) is suitable for machining complex shapes and sizes in conductive metals. The present research focused on the machining of aluminium 6061 with 6% wt boron carbide metal matrix composite (A6061/6%64C MMC). The input process parameters are designed based on the central composite design (CSD) and optimized using response surface methodology. The maximum material removal rate (MRR), minimum surface roughness (SR), and minimum electrode wear rate (EWR) are obtained from the analysis of variance (ANOVA) and are analyzed using the response surface method (RSM). The percentage improvement in MRR, SR, and EWR were calculated. The combination of parameters for the optimized results was obtained and the results show improvement in predicted results. An increase of 0.167% in MRR and 9.31%, 2.61% reduction in EWR and SR respectively were obtained in the predicted results. (C) 2020 Elsevier Ltd. All rights reserved.