Experimental Analysis of Al–TiC Sintered Nanocomposite on EDM Process Parameters Using ANOVA

Abstract

The size minimization of titanium carbide (TiC) particles was done by high-energy mechanical milling. Later Al and TiC powders were mixed to frame cylindrical preforms with 95% density using a die set. The cylindrical preform was sintered in a muffle furnace (575°C) and subsequently cooled. Characterization was done using scanning electron microscope (SEM), field emission scanning electron microscope, and energy-dispersive spectrum. An electrical discharge machining (EDM) and L9 orthogonal array was used to perform the experiments. The present investigation was carried out to optimize parameters such as current, pulse-on time, and gap voltage on metal removal rate (MRR) and tool wear rate (TWR) during EDM of as-sintered Al–5% reinforced with ≤200 nm and 2 µm TiC particle reinforcement. The rationality of the experimental plan and the effect of electrode wear ratio based on TiC particle addition were analyzed using analysis of variance (ANOVA) with consideration to MRR and TWR. The recast layer evolution during EDM process was assessed by SEM analysis.