Surface Integrity analysis in Wire-Cut Electric Discharge Machining of Al 6063/Al2O3 Metal Matrix Composite through Response Surface Methodology

Abstract — The development of new, superior engineering materials and the need for precise and low-volume production have made the wire electrical discharge machining (EDM) an important manufacturing process to meet such demands. This research investigates the effect of pulse on-time, pulse off-time and servo feed, three important WEDM process in obtaining good surface finish, optimized material removal rate and kerf on newly formulated Aluminum 6063/Al2O3 composite. Stir casting process is adopted for casting the composite plates with varying mass percentage of alumina (3%, 6%, 9%). The distribution of alumina and aluminium is examined by microstructure analysis, and the material is tested for its mechanical properties such as tensile strength and hardness. The effects of the parameters on the responses were evaluated by response surface methodology, which is based on optimization results. On the basis of optimization results it has been found that a pulse duration (Ton) of 3μs & pulse off time (Toff) 17μs and servo feed 7mm/min, which are the best combination of this analysis